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505 Digital Governor for Steam Turbines with Single or Split-Range Actuators
Volume 1
Manual 85017V1B
WARNING
Read this entire manual and all other publications pertaining to the work to be performed before installing, operating, or servicing this equipment. Practice all plant and safety instructions and precautions. Failure to follow instructions can cause personal injury and/or property damage. The engine, turbine, or other type of prime mover should be equipped with an overspeed shutdown device to protect against runaway or damage to the prime mover with possible personal injury, loss of life, or property damage. The overspeed shutdown device must be totally independent of the prime mover control system. An overtemperature or overpressure shutdown device may also be needed for safety, as appropriate.
CAUTION
To prevent damage to a control system that uses an alternator or battery-charging device, make sure the charging device is turned off before disconnecting the battery from the system. Electronic controls contain static-sensitive parts. Observe the following precautions to prevent damage to these parts. Discharge body static before handling the control (with power to the control turned off, contact a grounded surface and maintain contact while handling the control). Avoid all plastic, vinyl, and Styrofoam (except antistatic versions) around printed circuit boards. Do not touch the components or conductors on a printed circuit board with your hands or with conductive devices.
IMPORTANT DEFINITIONS
WARNINGindicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTIONindicates a potentially hazardous situation which, if not avoided, could result in damage to equipment. NOTEprovides other helpful information that does not fall under the warning or caution categories.
Woodward Governor Company reserves the right to update any portion of this publication at any time. Information provided by Woodward Governor Company is believed to be correct and reliable. However, no responsibility is assumed by Woodward Governor Company unless otherwise expressly undertaken.
Manual 85017V1
Contents
ELECTROSTATIC DISCHARGE AWARENESS .................................................. V CHAPTER 1. GENERAL INFORMATION ........................................................... 1
Introduction.............................................................................................................1 General Description................................................................................................3 505 Inputs and Outputs ..........................................................................................5 Control Overview ....................................................................................................8 Speed Control.........................................................................................................8 Auxiliary Control .....................................................................................................8 Load Sharing Input .................................................................................................9 Cascade Control.....................................................................................................9 Valve Limiter.........................................................................................................10 Starting Features ..................................................................................................10 Critical Speed Avoidance .....................................................................................11 Block Diagrams ....................................................................................................11 Keypad and Display..............................................................................................14 Watchdog Timer/CPU Fault Control.....................................................................16
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Contents
CHAPTER 5. 505 OPERATION ...................................................................112
Run Mode Architecture...................................................................................... 112 Keypad and Display........................................................................................... 116 Run Mode Front Panel Keys ............................................................................. 116 Starting Procedures........................................................................................... 117 Speed Key Screens........................................................................................... 118 Overspeed Test Function .................................................................................. 122 F3 and F4 Keys ................................................................................................. 123 Limiter (LMTR) Key Screens ............................................................................. 123 Actuator (ACTR) Key Screens .......................................................................... 124 Control (CONT) Key Screens............................................................................ 125 Dynamics (DYN) Key Screens .......................................................................... 127 Stop Key Screens.............................................................................................. 128 Auxiliary (Aux) Key Screens .............................................................................. 128 Remote/Speed Bias (RMT) Key Screens.......................................................... 131 Unit Load (KW) Key Screens ............................................................................ 134 Cascade (CAS) Key Screens ............................................................................ 135 Alarms................................................................................................................ 137 Trips................................................................................................................... 138 Speed, Cascade, and Auxiliary Dynamics Adjustments ................................... 139
Modbus * Communications.............................................................................. 143 Port Adjustments ............................................................................................... 146 505 Control Modbus Addresses ........................................................................ 146 Specific Address Information............................................................................. 157
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2.
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CAUTION
To prevent damage to electronic components caused by improper handling, read and observe the precautions in Woodward manual 82715, Guide for Handling and Protection of Electronic Controls, Printed Circuit Boards, and Modules.
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WARNING
Explosion hazardDo not connect or disconnect while circuit is live unless area is known to be non-hazardous. Explosion HazardSubstitution of components may impair suitability for Class I, Division 2.
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AVERTISSEMENT
Risque dexplosionNe pas raccorder ni dbrancher tant que linstallation est sous tension, sauf en cas lambiance est dcidment non dangereuse. Risque dexplosionLa substitution de composants peut rendre ce matriel inacceptable pour les emplacements de Classe I, Division 2.
WARNING
Do not use any test points on the power supply or control boards unless the area is known to be non-hazardous.
AVERTISSEMENT
Ne pas utiliser les bornes dessai du block dalimentation ou des cartes de commande moins de se trouver dans un emplacement non dangereux.
9. CONTROLLED STOP: Made the Controlled Stop abort if speed raise/lower is selected or another control mode is selected. This can be tuned-out by setting CNTRL_STOP.RL_STOP.IN_2=*false in the debug mode. 10. ANALOG INPUTS: Changed max setting on the delay times tunable range from 3 ms to 3000 ms. The analog input failure delay setting is defaulted to zero but can be adjusted up to 3000 ms using the debug mode MAIN.AIx.LATCH_DLY where x is the analog input number. Added a tunable single pole filter (LAG) to each analog input. Output/input = 1/(1+st) where t = 1/(2(pi)f) = LAG_TAU. The Lag-tau is defaulted to zero but can be adjusted in the debug mode using MAIN.AIx_LAG.LAG_TAU where x is the analog input number (1-6).
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General Description
General
The 505 microprocessor-based control is designed to control single or dual (split range) actuator steam turbines (extraction steam turbines require the 505E version). The 505 is field programmable which allows a single design to be used in many different control applications and reduces both cost and delivery time. It uses menu driven software to instruct site engineers on programming the control to a specific generator or mechanical drive application. The 505 can be configured to operate as a stand-alone unit or in conjunction with a plants Distributed Control System.
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Communications
The 505 can communicate directly with plant Distributed Control Systems and/or CRT based operator control panels, through two Modbus communication ports. These ports support RS-232, RS-422, or RS-485 communications using ASCII or RTU MODBUS transmission protocols. Communications between the 505 and a plant DCS can also be performed through hardwired connections. Since all 505 PID setpoints can be controlled through analog input signals, interface resolution and control is not sacrificed.
Additional Features
The 505 also provides the following features: First-Out Trip Indication (5 total trip inputs), Critical Speed Avoidance (2 speed bands), Auto Start Sequence (hot & cold starts), Dual Speed/Load Dynamics, Zero Speed Detection, Peak Speed Indication for Overspeed trip, and Isochronous Loadsharing between units (with a DSLC control).
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Control Outputs
Two actuator outputs with linearization curves; the second actuator output can be used as an extra readout if not used as an actuator output. Six 420 mA outputs, for meters or other readouts. Eight Form-C relay contact outputs, six that are configurable. The two dedicated relay outputs are for shutdown and alarm indication.
Control Interfaces
Two Modbus ports, to be used as control interfaces. The protocol can be either ASCII or RTU and the communications can be RS-232, RS-422, or RS-485. One computer (PC) port to be used for program configuration storage. An overview of the 505 functions is shown in Figure 1-3. Use this block diagram to match the control features to the site-specific application required.
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Control Overview
The 505 has two independent control channels, the speed/load and auxiliary controllers. The outputs of these two controllers are low-signal-selected (LSS) with another channel, the valve limiter. The output of the LSS directly sets the position of the actuator drivers output. In addition to these channels, the speed/load controller can be manipulated by another controller, the cascade controller. The cascade controller is cascaded into the speed controller, whereby the speed controller setpoint is changed directly by the cascade controller output. The auxiliary controller can act as either a control channel or as a limiting channel. All three of these PID controllers have the option of utilizing an analog input signal to remotely position their setpoints. Additional features of the 505 include frequency control, isochronous loadsharing (with a DSLC), critical speed avoidance, idle/rated control and an automatic start sequence. There are two serial communications ports which can be used to monitor and control the turbine using Modbus protocol.
Speed Control
The speed control receives a turbine speed signal from one or two magnetic pickups or proximity probes. The speed PID (proportional, integral, derivative) control amplifier then compares this signal to the speed setpoint to generate an output signal to the actuator (through a low signal select bus). The speed controls setpoint is adjustable with raise or lower commands through the keypad on the front of the control, remote contact inputs or the communication line. The setpoint can also be directly set by entering the new setpoint from the keypad or through either Modbus communications. In addition, an analog input can be programmed to remotely position the speed setpoint.
Auxiliary Control
The Auxiliary control channel can be used to either control a parameter or limit a parameter. The Auxiliary PID controller can be used to control or limit unit load/power, plant import/export levels, inlet pressure, exhaust pressure, temperature or any other process directly related to turbine load. The Auxiliary input is a 420 mA current signal. The Auxiliary PID control amplifier compares this input signal with a setpoint to produce a control output to the digital LSS (low-signal select) bus. The LSS bus sends the lowest signal to the actuator driver circuitry. 8 Woodward
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The Auxiliary setpoint is adjustable with raise or lower commands through the keypad on the front of the control, through remote contact inputs or through the communication links. Also, the setpoint can be directly set by entering the new setpoint from the keypad or through either Modbus communications. In addition, an analog input can be programmed to remotely position the Auxiliary setpoint.
Cascade Control
The cascade control can be configured to control any system process, related to or affected by turbine speed or load. Typically this controller is used as a turbine inlet or exhaust pressure controller. The cascade control is a PID controller that compares a 420 mA process signal with the cascade setpoint. The PID controller sets the speed controller setpoint until the process signal and the setpoint match. The cascade setpoint is adjustable with raise or lower commands through the keypad on the front of the control, the remote contact inputs, or the communication links. Also, the setpoint can be directly set by entering the new setpoint from the keypad or through Modbus communications. In addition, a remote cascade setpoint analog input can be programmed to remotely position the cascade setpoint.
Manual 85017V1
Valve Limiter
The valve limiter limits the actuator output signal or valve position to aid in starting up and shutting down a turbine. The output of the valve limiter is lowsignal-selected with the output of the speed/load and auxiliary control channels. The control or limiter channel asking for the lowest valve position will control valve position. Thus, the valve limiter limits the maximum valve position. The valve limiter can be adjusted through the keypad, external contact closures, or Modbus commands. The valve limiter can also be used to troubleshoot system dynamics problems. If it is believed that the 505 is the source of system instability, the valve limiter can be positioned to manually take control of the valve position. Care should be taken when using the valve limiter in this fashion, so as to not allow the system to reach a dangerous operating point.
Starting Features
The 505 provides options for three different starting modes: automatic, semiautomatic, and manual. One of these modes must be programmed to get the turbine from a shutdown state to speed control at minimum speed. The start mode configured and minimum governor controlling speed will depend on normal plant starting procedures and turbine manufacturers recommendations. If an idle speed is programmed (either idle/rated or auto start sequence modes), the 505 can provide automatic speed control and critical speed avoidance. A Run command can be given through the 505 keypad, a remote contact input, or Modbus communications. In addition, an optional Start Permissive contact input can be programmed to prevent a start if, for example, the trip-throttle or stop valve is not closed.
Idle/Rated
The idle/rated function gives an operator the ability to move between a programmed idle speed and a programmed rated speed at a configured rate. The selection of idle or rated speed setpoint positions can be made through the front panel keypad, through remote contact inputs, or through the Modbus communications links. The idle/rated function can also be programmed as a ramp-to-rated function only.
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The auto start sequence can be stopped and started, if desired, by programming and using the auto start sequence halt/continue commands. The selection of halt or continue can be made through the 505 keypad, remote contact inputs or Modbus communications. In addition, the auto start sequence can be programmed to automatically halt at each idle setpoint.
Block Diagrams
Overviews of possible 505 configurations are shown in Figures 1-5 through 1-7. Use these block diagrams to match the control features to the site-specific application requirements. Figure 1-4 lists symbols and their respective explanations. The Cascade and auxiliary PIDs are optional controllers, and are shown in the following diagrams for PID relationship purposes only.
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RAISE LOWER
LSS
SCALING ACTUATOR DRIVER 1
VALVE LIMITER
ACTUATOR DRIVER 2
Figure 1-5. Single or Split-Range Turbine Configurations (Speed PID with Remote Setpoint)
TIE BREAKER GEN BREAKER ENABLE CASCADE SETPOINT CASCADE INPUT
PERCENT TO RPM CONVERSION
CASC
LSS
SPEED SCALING ACTUATOR DRIVER 1
855669 021231
Figure 1-6. Single or Split-Range Turbine Configurations (Auxiliary PID Configured as a Limiter)
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KW/UNIT LOAD
CASC
SPEED
LSS
ACTUATOR DRIVER 1
SCALING
AUX
VALVE LIMITER
ACTUATOR DRIVER 2
Figure 1-7. Single or Split-Range Turbine Configurations (Auxiliary PID Configured as a Controller)
Manual 85017V1
A description of each keys function follows. Some descriptions refer to the function blocks contained in the programming (Chapter 4) and operating flowcharts (Chapter 5). SCROLL : The large diamond shaped button in the middle of the keypad with arrows at each of its four corners. The < > (scroll left, right) moves the display left or right through the function blocks of the Program or Run Mode. The , (scroll up, down) moves the display up or down within a function block of the Program or Run Mode. SELECT: The Select key is used to select control of the 505 displays top or bottom line variable. The @ sign is used to indicate which line (variable) can be adjusted by the adjust keys. Only when there is a changeable variable on both lines (dynamics, valve calibration modes) does the select key and @ sign determine which line variable can be adjusted. When there is only one variable per screen the select key and @ signs position are irrelevant. ADJ (adjust): In the Run Mode, moves any adjustable parameter up (larger) and moves any adjustable parameter down (smaller). PRGM (program): When the control is shutdown this key selects the Program Mode. While in the Run Mode this key selects a Program Monitor Mode. In the Program Monitor Mode the program can be viewed but not changed. RUN: Initiates a turbine run or start command from the (CONTROLLING PARAMETER/PUSH RUN or PRGM) state. STOP: Initiates a controlled turbine shutdown (Run Mode) once verification is given. The Stop command can be disabled through a Service Mode setting (under Key Options). RESET: Resets/clears Run Mode alarms and shutdowns. Pressing the key also returns the control to the (CONTROLLING PARAMETER/PUSH RUN OR PRGM) status after a shutdown. 0/NO: Enters 0/NO or disable. 1/YES: Enters 1/YES or enable. 2/ACTR (actuator): Enters 2 or displays the actuator position (Run Mode). 3/CONT (control): Enters 3 or displays the parameter which is in control (Run Mode); press the Scroll down arrow to display the controls last trip cause, highest speed reached, and local/remote status (if used). 4/CAS (cascade): Enters 4 or displays the cascade control information (Run Mode). 5/RMT (remote): Enters 5 or displays the remote speed setpoint control information (Run Mode). Woodward 15
505 Digital Governor 6/LMTR (valve limiter): Enters 6 or displays the valve limiter information (Run Mode) 7/SPEED: Enters 7 or displays the speed control information (Run Mode). 8/AUX (auxiliary): Enters 8 or displays the auxiliary control information (Run Mode).
Manual 85017V1
9/KW (load): Enters 9 or displays the kW/load or first stage pressure information (Run Mode). CLEAR: Clears Program Mode and Run Mode entries and takes control out of its present mode. ENTER: Enters new values in the Program Mode, and allows the direct entry of specific setpoint values in the Run Mode. DYNAMICS (+/): Accesses the dynamic settings of the parameter controlling the actuator position in the Run Mode. The dynamics adjustments can be disabled through a Service Mode setting (under Key Options). This key will also change the sign of a value being entered. (DECIMAL KEY) Enters decimal point in number being entered from front panel. ALARM (F1): Displays the reason for any alarm condition (last/newest alarm) when the keys LED indicator is illuminated. Press the Scroll down arrow (diamond key) to display additional alarms. OVERSPEED TEST ENABLE (F2) : Permits the speed reference to be raised beyond the maximum controlling speed set point to test either the electrical or mechanical overspeed trip. F3 (function key): Programmable function key for enabling or disabling programmable control functions. F4 (function key): Programmable function key for enabling or disabling programmable control functions. EMERGENCY SHUTDOWN BUTTON: Large red octagonal button on the front of the enclosure. This is an Emergency Shutdown command for the control.
Manual 85017V1
WARNING
Explosion hazardDo not connect or disconnect while circuit is live unless area is known to be non-hazardous. Explosion HazardSubstitution of components may impair suitability for Class I, Division 2.
AVERTISSEMENT
Risque dexplosionNe pas raccorder ni dbrancher tant que linstallation est sous tension, sauf en cas lambiance est dcidment non dangereuse. Risque dexplosionLa substitution de composants peut rendre ce matriel inacceptable pour les emplacements de Classe I, Division 2.
WARNING
Do not use any test points on the power supply or control boards unless the area is known to be non-hazardous. Woodward 17
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AVERTISSEMENT
Ne pas utiliser les bornes dessai du block dalimentation ou des cartes de commande moins de se trouver dans un emplacement non dangereux.
Enclosures
Figure 2-1 shows 505 control layout and mounting pattern. The 505 digital control is housed in a flush mount enclosure. This enclosure is designed for installation within a control room panel or cabinet, and by itself, cannot be bulkhead-mounted. The 505 package, once properly installed within a NEMA4X panel or cabinet meets NEMA 4X ratings. A gasket is attached to the rear side of the packages bezel to properly seal the 505s face-plate to a panel. All field wiring connects to the 505 through removable terminal blocks located on the 505s back side. The 505s internal components are industrial grade. These components include the CPU (central processing unit), its memory, the switching power supply, all relays, all Input/Output circuitry, and all circuitry for the front panel display, touch keypad, and the serial communications. An optional NEMA-4X enclosure is available to allow the 505 to be bulkhead mounted (Figure 2-2). The 505 digital control mounts on the front door of the enclosure. This allows for easy service access through the enclosures front door. This bulkhead mounted enclosure has two removable gland plates attached to the bottom. A user may cut appropriately sized conduit openings (up to 1.5) as required, in the removable gland plates for wiring access. For EMI reasons, it is recommend that all low-current wire (terminals 52 through 121) be separated from all high-current wire (terminals 1 through 51).
Mounting
The standard 505 package must be mounted to allow sufficient room for wiring access. Eight front panel screws permit secure mounting. The standard 505 weighs approximately 4 kg (9 lb), and has an operating range of 25 to +65 C ambient air temperature. The optional enclosure permits the control to be bulkhead mounted. See Figure 2-2 for mounting dimensions. This enclosure weighs approximately 10 kg (22 lb), and allows an operating range of 20 to +60 C ambient air temperature.
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Electrical Connections
Refer to Figure 2-7 for a representative 505 I/O interface schematic, and Volume 2 of this manual, for hardware Input/Output specifications. All inputs and outputs to the 505 are made through CageClamp terminal blocks on the bottom of the 505 package. For EMI reasons, it is recommend that all lowcurrent wire (terminals 52 through 121) be separated from all high-current wire (terminals 1 through 51). The terminal blocks are screwless CageClamp style blocks. The spring clamp can be actuated by using a standard 3 mm or 1/8in flat bladed screwdriver or a snap-on thumb lever (Figure 2-5). Two snap-on thumb levers are provided with the 505 unit. The 505 terminal blocks accept wires from 0.082.5 mm (2712 AWG) wire. Two 0.8 mm (18 AWG) or three 0.5 mm (20 AWG) wires can be easily installed in each terminal. The 505 controls terminal blocks are designed to be removed by hand. After 505 input power is disconnected, the terminal blocks can be removed one at a time by prying them off using ones finger tips. When removing a terminal block, never pull on the wires connected to the terminal block. Wires for the fixed mounted power terminals should be stripped 56 mm (0.22) long. Wire for the pluggable I/O terminals should be stripped 89 mm (0.33) long. When a bulkhead enclosure is required, all electrical connections must be made through the gland plates provided on the bottom of the bulkhead mount enclosure to the terminal blocks inside. See Figure 2-2.
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Power Supplies
The 505 is available with three different input power source selections. The part number of the 505 depends on the rating of the input power source it can accept. The ratings of the required input power source on each unit can be identified by the back panel sticker or control part number. The sticker will show the correct source power ratings for each unit by a punched hole next to the rating. Refer to Volume 2 for all power supply specifications. The 505s input power supply terminal blocks accept wires from 0.082.5 mm (2712 AWG) wire. Internal fuses, in series with each input power trace, are used to protect the 505s input circuitry. All fuses are rated as slow-blow type fuses. These fuses are accessed by taking the 505s back cover off and are located on its power supply module (bottom module). Refer to Figure 2-8 for fuse locations. The ratings for the different sources of input power accepted by the 505 and the 505s internal fuse sizes are listed as follows: 1832 Vdc 88132 Vac @ 4763 Hz or 90150 Vdc 180264 Vac @ 4763 Hz (6.25 A internal fuse, 77 VA maximum draw) (2.5 A internal fuse, 143 VA maximum draw) (1.5 A internal fuse, 180 VA maximum draw)
Each 505 requires a power source capable of a certain output voltage and current. In most cases this power rating is stated in Volt-Amps (VA). The maximum VA of a source can be calculated by taking the rated output voltage times the maximum output current at that voltage. This value should be greater than or equal to the 505 VA requirement.
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505 power supply holdup times are determined by the 505 power supply and input power used. The below times are based on worse case conditions (88 Vac with a possible range of 88132 Vac when power is lost). These holdup times should be used when the 505 is powered by an Uninterruptible Power Source (UPS) to evaluate if the UPSs switch over time is quick enough avoid a system trip. A UPSs switch-over time must be less than the below specified holdup times: Power Supply Holdup Times 1832 Vdc Power Supply 88132 Vac @ 4763 Hz or 90150 Vdc Power Supply 180264 Vac @ 4763 Hz Power Supply
A 24 V power supply is available, within the 505, to power external transducers or devices. This supply has two breaker protected output channels. One power supply channel (VA1) is capable of providing 24 Vdc 10%, @ 200 mA maximum output current, to power 505 current inputs and auxiliary devices. Power connections can be made through terminals 55, 59, 63, 70, and 74 with terminal 78 as the common. Refer to Figure 2-7.
WARNING
The total current draw through terminals 55, 59, 63, 70, and 74 cannot exceed 200 mA or the 505s internal power supply breaker (CB1) will open resulting in a possible CPU reset and trip condition. All load must be removed from the specified terminals to allow the breaker to reset. The second power supply channel is capable of providing 24 Vdc 10%, @ 200 mA maximum output current, to power 505 current outputs and auxiliary devices. Power connections can be made through terminals 85, 88, 91, 97, 100, and 103 with terminal 78 as the common. Refer to Figure 2-7.
WARNING
The total current draw through terminals 85, 88, 91, 97, 100 and 103 cannot exceed 200 mA or the 505s internal power output breaker (CB2) will open resulting in a possible CPU reset and trip condition. All load must be removed from the specified terminals to allow the breaker to reset.
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A proximity probe may be used to sense very low speeds. With a proximity probe, speed can be sensed down to 0.5 Hz. The input voltage must be between 16 and 28 Vdc for proper operation. The speed sensor input channels are isolated, so either channel can be jumper configured for a MPU or proximity probe. By being able to sense turbine speed down to this level, the 505 can be programmed to turn on or off a turbine turning gear, via a relay output. See Figure 2-7 for proximity probe wiring schematic. It is not recommended that gears mounted on an auxiliary shaft coupled to the turbine rotor be used to sense turbine speed. Auxiliary shafts tend to turn slower than the turbine rotor (reducing speed sensing resolution) and have coupling gear back-lash, resulting in less than optimum speed control. For safety purposes it is also not recommend that the speed sensing device sense speed from a gear coupled to a generator or mechanical drive side of a systems rotor coupling. An application may use two of the same type of speed probes, or two different types of speed probes (one MPU and one proximity probe). Both speed sensing inputs use the same programmed gear ratio and number of teeth to calculate speed, thus the speed probes used should sense speed from the same gear. The 505 can be programmed to sense only one speed input signal. However, it is recommended that the 505 be programmed to sense two speed inputs, and that two speed probes be used with all applications to increase system reliability.
NOTE
The speed signal that the 505 can accept must be within the following limits: (T x M x R)/60 must be < 15000 Hz T = Gear Teeth M = Overspeed Test Limit Setting R = Gear Ratio If the signal is not within these limits, the 505 will respond with a speed sensor frequency error during the program checking procedure.
Contact Inputs
In general, contacts must change state for a minimum of 15 milliseconds for the control to sense and register a change in state. All contact inputs accept dry contacts. Contact wetting voltage is available through terminals 4, 5, 6, 7, 8, 9, and 10. If desired, an external 1826 Vdc power source can be used for the circuit wetting voltage. In this case terminal 11 (contact input common) must be connected to the external power sources common to establish a common reference point. Each contact input pulls 2.5 mA when closed and requires at least 1 mA and 14 V to recognize a closure command. See Figures 2-6 and 2-7 for wiring information, and Volume 2 for input specifications.
WARNING
The total current draw through terminals 4, 5, 6, 7, 8, 9, and 10 cannot exceed 100 mA or the 505s internal power output breaker (CB5) will open resulting in a possible CPU reset and trip condition. all load must be removed from the specified terminals to allow the breaker to reset.
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If the 16 contact inputs available, four have functions already assigned to them (preset) and cannot be changed, the other 12 are user-configurable. The Preset Contact Inputs are: External Emergency Shutdown External Reset Raise Speed Setpoint Lower Speed Setpoint Before starting, the External Emergency Shutdown contact must have an external switch wired in and closed or be jumpered closed. The control will initiate an emergency shutdown any time the contact is opened. This input is typically tied into the systems trip string and provides trip feedback to the control. The external reset contact can be used to remotely clear alarms and return the control to the (Controlling Parameter/Push Run or Prgm) state after a shutdown. The raise and lower speed setpoint contact inputs can be used to remotely raise and lower speed or load. Applications requiring external contact inputs must have the desired function assigned or configured to a specific input. There is a choice of twelve possible contact inputs and twenty-seven programmable functions. If the 505 is configured for a generator application two of the contacts must be configured for the Generator and Utility breaker inputs. The Generator Breaker contact must be wired so it is closed when the generator breaker is closed. The Utility Tie Breaker contact must be wired so it is closed when the utility tie breaker is closed. Refer to Chapter 4 of this manual for a complete list of programmable contact input functions.
Analog Inputs
Analog inputs # 1, 2, 3, 4, and 5 may be used with two-wire ungrounded (loop powered) transducers or isolated (self-powered) transducers. Jumpers are available to match the analog input circuit to the transducer being interfaced with, or the power supply common may be jumpered on the terminal block. Verification of jumper location is recommended before system startup or operation. See Table 2-1 for jumper options and Figure 2-4 for jumper locations. Because inputs 1-5 are not fully isolated, care must be taken in their application and maintenance to avoid ground-loop type problems. If interfacing to a nonisolated device with one of these inputs, the use of a loop isolator is recommended to break any return current paths, which could result in erroneous readings. Analog input # 6 is a fully isolated input and is designed to be used with a nonisolated source such as a Distributed Control System (DCS). This input does not use or have jumpers for hardware configuration options. Refer to Figure 2-7, Option #1 for correct wiring configuration. All six analog inputs are programmable, and have an input impedance of 200 . Refer to Chapter 4 of this manual for a complete list of programmable analog input options.
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Analog Outputs
Applications using a 505 current output must have the desired analog value assigned or configured to a specific output. There is a choice of six possible 4 20 mA output drivers of which to use to display a parameter externally. Optionally, if Actuator Driver #2 is not being utilized to drive an actuator, it can be programmed to function as a 420 mA driver to display one of the values listed below. The analog output connections for the 505 are shown in Figure 2-7. All 505 analog outputs can drive into a maximum of 600 . Refer to Chapter 4 of this manual for a complete list of programmable analog output options.
Actuator Outputs
Two actuator outputs are available and programmable to interface with Woodward Governor Company actuators (20160 mA drive currents) or nonWoodward actuators (420 mA drive currents). Each actuator output can be individually configured to interface with Woodward or non-Woodward type actuators. Actuator drive current is selected in the Program Mode. Maximum impedance for each 4 to 20 mA actuator output driver is 360 (actuator impedance + wire resistance). Maximum impedance for each 20 to 160 mA actuator output is 45 (actuator impedance + wire resistance). Dither is available for either output. Each actuator driver senses the drive current to allow over- and under-current shutdowns. The 505 can be configured to use one or two actuators. If only one actuator is used and programmed, it must be wired to actuator #1s output terminals. If two actuators are used they can be programmed to operate in a staggered or parallel mode. If the Actuator #2 Offset percentage is set to 50% then actuator #2 will begin opening when actuator #1 reaches 50%. The control will continue to open both valves to 100% with a position difference of 50%. To operate the two actuators in parallel set Actuator #2 Offset percentage to zero. This will force both actuators to operate at the same level or in parallel. Optionally, if actuator #2 driver is not used as an actuator output driver it can be used as a 420 mA current output to drive a meter or DCS input. Refer to Chapter 4 of this manual for a complete list of programmable analog output options. In addition, an eleven (11) point actuator linearization adjustment curve is available through the Service Mode for each actuator output (see Service Mode adjustments in volume 2).
Relay Outputs
There are eight relay outputs available from the 505. All relay contacts are Form C type contacts. For relay load ratings, refer to Appendix A in Volume 2.
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NOTE
Before installation verify that the 505s relay contacts meet the power requirements of the circuit with which it is being interfaced. Interposing relays are required, in cases where the interfaced circuit demands relay contacts with a higher power rating. If interposing relays are required, it is recommended that interposing relays with surge (inductive kick-back) protection be used. Improper connection could cause serious equipment damage. Two of the eight relay outputs available are dedicated to a function and are as follows: Alarm relayenergizes for any alarm condition Shutdown relayde-energizes for any shutdown condition The remaining six relays can be programmed to energize upon a function change of state or an analog value level. Applications requiring programmable relay outputs must have the desired switch condition, or specific analog value assigned to them. Refer to Chapter 4 of this manual for a complete list of programmable relay output options.
Serial Communications
There are three serial communications ports on the 505. Ports one and two are for Modbus communications and can be configured for RS-232, RS-422, or RS485 communications. Figures 2-10, 11, and 12, show the communications port connections for ports #1, and #2. Ports one and two are accessed though terminal blocks located on the 505s back side. RS-422 and RS-485 communication lines can function up to a length of 4000 feet Refer to the Modbus section of this manual for a list of all the commands and parameters available through ports one and two. The third port, utilizing a 9-pin Sub-D connector, is dedicated for uploading and downloading unit configuration values at the factory. The Program Mode can not be accessed through the communication ports. Program configuration must be done from the keypad on the front of the control.
Modbus Wiring
The 505 control can communicate to two devices via RS-232, RS-422, RS-485 using an ASCII or RTU Modbus transmission protocol. The communications port is brought out to terminal blocks for wiring. Each communications mode is wired to different terminals. The following sections identify the terminal landings required for each mode. RS-232 Wiring A RS-232 link is limited to a distance of 50 feet. The 505 control utilizes terminal blocks 114-117 and 106-109 for RS-232 connections. Figure 2-10 shows typical RS-232 communications connection. The transmit data (TXD), receive data (RXD), and signal ground (SIG GND) must be properly connected as shown. In addition the shield (SHLD) should be connected in at least one location..
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RS-422 Wiring An advantage of RS-422 communications is that it uses a differential voltage and can accommodate much longer transmission distances. A RS-422 link can communicate up to a distance of 4000 feet. The 505 control utilizes terminal blocks 108-113 and 116-121 for RS-422 connections. Figure 2-11 shows a typical RS-422 communications connection. The transmit data pairs (422T+ and 422T-), receive data pairs (422R+ and 422R-), and signal ground (SIG GND) must be properly connected as shown. In addition, the shield (SHLD) should be connected in at least one location. The last unit in the Modbus network chain, and only the last unit, should have its receiver terminated with a resistor. The 505 control has termination resistors built-in. See the jumper option chart (Table 2-1) to connect the termination resistor..
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RS-485 Wiring RS-485 communications can also accommodate transmission distances of up to a distance of 4000 feet. The 505 control utilizes terminal blocks 108-111 and 116-119 for RS-485 connections. Figure 2-12 shows a typical RS- 485 communications connection. The data lines (422R+/485+ and 422R-/485-) and signal ground (SIG GND) must be properly connected as shown. In addition, the shield (SHLD) should be connected in at least one location. The last unit in the Modbus network chain, and only the last unit, should have its receiver terminated with a resistor. The 505 control has termination resistors built-in. See the jumper option chart (Table 2-1) to connect the termination resistor.
Figure 2-13. Preferred Multipoint Wiring with a Separate Signal Ground Wire Woodward 33
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Non-isolated nodes may not have a signal ground available. If signal ground is not available, use the alternate wiring scheme as shown in Figure 2-14. The alternate way is to connect all circuit grounds of isolated nodes to the shield, and then connect the shield to earth ground at a non-isolated node.
Figure 2-14. Alternate Multipoint Wiring without a Separate Signal Ground Wire
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Turbine Start
The 505 has three turbine start modes (manual, semi-automatic or automatic) from which to choose from. One of these start modes must be chosen and programmed to perform a system startup. Once a RUN command is issued, the speed setpoint and valve limiter are manipulated automatically by the 505 or manually by the operator, depending on which start mode is selected. After a turbine start has been completed, turbine speed will be controlled at a minimum controlling speed. The minimum controlling speed may be idle if idle/rated is being used, low idle if the auto start sequence is used, or minimum governor if neither idle/rated or auto start sequence is used.
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A RUN command may be issued from the 505 keypad, an external contact, or through Modbus communications. If an External Run contact is programmed, a RUN command is issued when the contact is closed. If the contact is closed prior to start-up it must be opened and re-closed to issue a RUN command. If turbine speed is sensed when a RUN command is issued, the control will instantly match the speed setpoint to the sensed speed and continue towards the minimum controlling speed. In the event the sensed turbine speed is greater than the minimum controlling speed setting, the speed setpoint will match this sensed speed, the Speed PID will control at this point, and the control will wait for further action to be taken by the operator (unless auto start sequence is configured). If the turbine speed is first sensed within a critical speed avoidance band when Run is selected, the speed setpoint will match the actual speed and increase to the upper end of the critical avoidance band and wait for action to be taken by the operator.
Start Permissive
An external contact may be used as a turbine startup permissive. When programmed for this functionality, the contact input must be closed in order for a RUN command to be executed. Should the contact be open when a RUN command is given, an alarm will be issued and the 505 display will indicate that the start permissive was not met (Start Perm Not Met). The alarm does not need to be cleared but the contact must be closed before the 505 will accept the RUN command. After RUN has been accepted, the start permissive contact will have no effect on operation. If used, this input is typically connected to a Trip & Throttle valves closed limit switch to verify that it is in the closed position before a turbine startup is performed.
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WARNING
The trip-and-throttle valve must be closed before pushing the RUN key in Manual Start mode. If a RUN command is given while the trip- and-throttle valve is open, there exists a possibility of turbine runaway with resultant serious injury or loss of life.
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100%
VALVE LIMITER
SPEED ACTUATOR
TIME
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100%
VALVE LIMITER
SPEED ACTUATOR
TIME
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VALVE LIMITER
SPEED ACTUATOR
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Critical speed bands are defined in the Program mode under the SPEED SETPOINT VALUES header. All critical speed band settings must be set below the Min Governor Speed Setpoint. A configure error will occur if an idle setpoint is programmed within a critical speed band. The rate in which the speed setpoint moves through a critical speed band is set by the Critical Speed Rate setting. The Critical Speed Rate setting should be set at but no higher than the turbines rated maximum acceleration rate.
Idle/Rated
The 505 is equipped with an Idle/Rated function which allows the 505 to automatically ramp turbine speed to the applications Rated speed setting. When deselected, the turbine speed ramps down to the applications Idle speed setting (as defaulted in the Service Mode). The Idle/Rated function can be used with any 505 start mode (manual, semiautomatic, automatic). When a RUN command is issued, the speed setpoint will ramp from zero rpm up to and hold at the Idle Setpt setting. When a rampto-rated command is given, the speed setpoint ramps to the Rated Setpt setting at the Idle/Rated Rate. While ramping to a Rated speed, the setpoint can be stopped by a raise or lower speed command or a valid entered speed setpoint. The 505 will inhibit a ramp-to-idle speed or ramp-to-rated speed command, if the Generator Breaker is closed, Remote Speed Setpoint is enabled, Cascade PID is in control, or the Auxiliary PID is in control (as defaulted in the Service Mode). Alternatively, the 505s Idle Priority and Use Ramp to Idle Function Service mode settings can be configured to change the defaulted idle/rated logic.
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A Ramp-to-Idle speed or Ramp-to-Rated speed command may be selected from the 505 keypad, contact input, or Modbus communications. The last command given from any of these three sources dictates the function performed. If a 505 contact input is programmed to select between Idle or Rated speeds, Idle speed is selected when the contact is open and rated speed is selected when it is closed. The Idle/Rated contact can be either open or closed when a trip condition is cleared. If the contact is open, it must be closed to initiate a Ramp-to-Rated speed. If the contact is closed, it must be opened and re-closed to initiate a Ramp- to-Rated speed. When the turbine is used for mechanical drive applications, rated speed may be set at the minimum governor speed setting. When the turbine is used to drive a generator, the rated speed setting may be set at or between the minimum governor and synchronous speed settings. All pertinent Idle/Rated parameters are available through the Modbus links, refer to Chapter 6 for a complete listing.
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The 505 can be configured to utilize an Automatic Start Sequence to start the turbine. This sequencing logic allows the 505 to perform a complete controlled system startup from zero speed to rated speed. With this function, the turbines starting ramp rates and idle speed hold times depend on the length of time the unit was shutdown. This sequence logic may be used with any of the three start modes (manual, semiautomatic, automatic), and is initiated by a RUN command. With this function, when a RUN command is given, the Automatic Start Sequence ramps the speed setpoint to a low idle setpoint, holds at this setting for a duration, ramps the speed setpoint to a high idle setpoint, holds at this setting for a duration, then ramps the speed setpoint to a rated speed setting. All ramp rates and hold times are programmable for both hot start and cold start conditions. The control differentiates between hot and cold starts by using a hours-since-trip timer. This timer starts when a shutdown has been executed and turbine speed has decreased below the low idle speed setting.
With this sequence, a set of hot-start ramp rates and hold times is programmed for use when a RUN command is given and the turbine has been shutdown for less than the programmed HOT START time setting. A set of cold-start ramp rates and hold times is also programmed for use when a RUN command is given and the turbine has been shutdown for longer than the programmed COLD START time setting. If a turbine RUN command is given when the length of time the system has been shutdown is between the HOT START and COLD START time settings, the control will interpolate between the hot and cold programmed start values to determine starting rates and hold times.
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For example, if the unit had the following Automatic Start Sequence settings: COLD START ( > xx HRS) = 22 HRS HOT START ( < xx HRS) =2 HRS LOW IDLE SETPT = 1000 rpm LOW IDLE DELAY (COLD) = 30 MIN LOW IDLE DELAY (HOT) = 10 MIN HI IDLE SETPT = 2000 rpm RATE TO HI IDLE (COLD) =5 rpm/sec RATE TO HI IDLE (HOT) = 15 rpm/sec HI IDLE DELAY TIME (COLD) = 20 MIN HI IDLE DELAY TIME (HOT) = 30 MIN RATE TO RATED (COLD) = 10 rpm/sec RATE TO RATED (HOT) = 20 rpm/sec RATED SETPT = 3400 rpm If the unit was tripped for 12 hours, the 505 would interpolate between the Hot and Cold parameters and use the following rates and delays (viewed in the Service Mode): LOW IDLE DELAY = 20 MIN RATE TO HI IDLE = 10 rpm/sec HI IDLE DELAY = 10 MIN RATE TO RATED = 15 rpm/sec HOURS SINCE TRIP = 12 HOURS Based on the examples configuration and trip time, the speed setpoint would ramp to 1000 rpm at the Rate to Min setting and hold for 20 minutes, move to 2000 rpm at 10 rpm/sec and hold there for 10 minutes, and lastly, move to 3400 at 15 rpm/sec. At 3400 rpm, the sequence would be completed. If the unit was tripped for 2 hours or less and restarted, the 505 would use the Hot Start parameters. If the unit was tripped for 22 hours or longer and restarted, the 505 would use the Cold Start parameters. . The Hours since Trip timer starts counting when the unit shuts down and the speed has coasted down below the low idle speed setting.
NOTE
The 505 will automatically set the hours-since-trip timer to its maximum setting of 200 hours to ensure a cold start is selected after a power up or upon exiting the Program mode. The hours-since-trip timer will reset only when the turbine speed has increased above the minimum governor speed setting. The Auto Start Sequence can be halted at any time from the 505 keypad, contact input or through Modbus. The sequence can be halted by a halt command, a raise or lower speed setpoint command, or when a speed setpoint is directly Entered from the 505 keypad or through Modbus communications. When the sequence is halted, the delay timers do not stop if they have already started counting down. The sequence will resume when a Continue command is issued. If there were 15 minutes remaining to hold at an idle speed and the Halt command was issued for 10 minutes before a issuing a Continue command, the sequence would remain at the idle speed for the remainder of the Hold Time which in this example is 5 minutes. The halting and continuing of the Auto Start Sequence can be performed through the 505 keypad, contact input, or Modbus. The last command given from any of these three sources determines the mode of operation. However, a shutdown condition will disable this function, requiring it to be re-enabled after a start-up has been performed. 44 Woodward
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If a 505 contact input is programmed to function as an Halt/Continue command, the sequence is halted when the contact is open, and continued when the contact is closed. The Halt contact can be either open or closed when a Reset command is given. If the contact is closed, it must be opened to allow the sequence to be halted. If the contact is open, it must be closed and reopened to issue a halt command. Alternatively, a relay can be programmed to indicate when the Auto Start Sequence is halted. An option is available to automatically halt the auto start sequence at the idle setpoints. This feature would result in the unit automatically stopping or halting at the low idle setpoint and at the high idle setpoint. If the unit is started and the speed is above the low idle setpoint, the sequence will initialize as halted. The sequence must be given a Continue command once halted. The hold timers are still active with this option. If Continue is selected and the hold timer has not expired, the sequence will remain in a timed wait until the hold timer has expired and then continue from that point. When the Auto Halt at Idle Setpts option is programmed, the Auto Start Sequence Continue contact input only requires a momentary closure to continue the sequence.
No Idle Programmed
If neither the Idle/Rated or Auto Start Sequence functions are programmed, the speed setpoint will ramp from zero to the minimum governor setpoint at the Rate To Min setting rate. Critical speed bands cannot be programmed with this configuration.
NOTE
The 505 is factory set (jumpers installed) to interface with passive MPUs, if proximity probes are used, the jumpers must be changed (see Chapter 2 for jumper options).
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Speed Control
While in the Speed Control mode, the Speed PID will control a turbine at the same speed or frequency regardless of the load it is supplying (up to the units load capability). With this configuration, no form of droop or second controlling parameter is used by the PID for stability or control. Refer to Figure 3-6. The following Speed PID mode descriptions are based on the 505 programs default settings. For information on how to change the 505s defaulted breaker logic, refer to Volume 2 of this manual. All pertinent speed control parameters are available through Modbus communications. See Chapter 6 for a list of all Modbus parameters.
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Frequency Control
The following Frequency Control mode descriptions are based on the 505 programs default settings. For information on how to change the 505s defaulted breaker logic, refer to Volume 2 of this manual. The Speed PID operates in the Frequency control mode when the generator breaker is closed and the utility tie breaker is open. In the Frequency control mode, the unit will operate at the same speed or frequency regardless of the load it is supplying (up to the units load capability). Refer to Figure 3-5. When breaker positions result in the Speed PID switching to Frequency control, the speed setpoint is instantly stepped to the last turbine speed (frequency) sensed before Frequency control was selected. This allows a bumpless transfer between modes. If the last speed sensed was not at the Rated Speed Setpoint (synchronous speed) setting, the speed setpoint will ramp to the Rated Speed Setpoint setting at a defaulted rate of 1 rpm/sec (tunable through the Service mode). In the Frequency control mode the speed setpoint can be varied with the Speed Setpoint Raise/Lower commands, as desired, to allow manual synchronization across a tie breaker to an infinite bus. See the Synchronization section in this Chapter. For indication purposes, a relay can be programmed to energize when the unit is in Frequency control.
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Because the 505s Speed PID and setpoint are used to control turbine speed and a second parameter, this second parameter (unit load) is normalized to allow all three terms (speed, setpoint, unit load) to be summed together within the PID summing junction. This normalization is based on a percentage of rated speed and creates a direct relationship between unit load and the Speed PIDs setpoint. Once unit load (0-100%) is represented as a percent of rated speed, the speed setpoint can be varied by this percent, above rated speed, to increase load from 0- 100% when paralleled to the utility. Unit load is converted to a percentage of rated speed as shown in the following example calculation: DROOP % x (gen load or valve position-%) x Rated Speed = Speed Setpoint change in rpm Example: 5% x 100% x 3600 rpm = 180 rpm For this example when paralleled to a utility bus, the speed setpoint can be adjusted from 3600 rpm to 3780 rpm to vary unit load from 0 to 100%. Droop feedback allows the Speed PID to control unit load (generator power or turbine valve position) once it is paralleled with a utility bus or other generating systems which do not have droop or loadsharing capability. When a turbine generator set is paralleled with a utility bus, the utility determines the unit frequency/speed, thus the governor must control another parameter. The 505 uses turbine inlet valve position (LSS bus position) or generator load as a second parameter to control when paralleled to an infinite bus.
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It is recommended that a Woodward Real Power Sensor or equivalent watt transducer be used to sense generator load and feed it back to the 505s KW input for KW droop control. However, if KW droop is not used or programmed, the 505 uses its LSS bus position to represent or sense turbine inlet valve position when paralleled with an infinite bus. If while controlling generator load, the KW input signal fails the 505 will issue an alarm and revert to turbine inlet valve position to control from. The generator load or turbine inlet valve position droop percentage cannot be set greater that 10%, and is typically set to 5%. To configure the 505 for generator load control when paralleled to a infinite bus, program the KW DROOP setting to YES, and program the 505 to accept an analog input from a Watt transducer sensing generator load.. To configure the 505 for turbine valve position control when paralleled to an infinite bus, program the KW DROOP setting to NO. The generator load or turbine inlet valve position droop percentage cannot be set greater that 10%, and is typically set to 5%. If the 505 is programmed to control unit load using turbine inlet valve position droop (LSS bus position), the 505 calculates load based on the valve position at the time the generator breaker was closed. This valve position is considered to be zero load. In a typical application where turbine inlet and exhaust pressures are at rated levels when the generator breaker is closed, this type of calculation allows unit load to be accurately sensed, and controlled. However, in an application where turbine inlet or exhaust pressures are not at rated levels when the generator breaker is closed, the considered zero load level will be incorrect when system pressures do reach rated levels. With this type of application it is recommended that the Minimum Load setpoint not be used. To disable the use of the Minimum Load Setpoint, configure the Use Min Load setting (under the Service modes BREAKER LOGIC header) to No.
Speed Setpoint
The Speed PIDs setpoint may be adjusted from the 505 keypad, external contacts, Modbus commands, or through a 420 mA analog input. A specific setpoint setting can also be directly entered through the 505 keypad or Modbus communications. The Cascade PID also directly controls this setpoint when it is used. The Speed PIDs setpoint may be adjusted a variety of ways. It can be adjusted up or down from the 505 keypad, external contacts, or through Modbus commands. It can be directly entered to a specific value from the 505 keypad or through Modbus commands. It can be remotely set by the Remote Speed Setpoint analog input or it can be manipulated by the Cascade controller to control the cascade input parameter. The speed setpoint range must be defined in the program mode. Program settings Min Governor Speed Setpoint and Max Governor Speed Setpoint define the normal operating speed range of the turbine. The speed setpoint cannot be raised above Max Governor Speed Setpoint setting unless an Overspeed Test is performed. Once the speed setpoint is taken above the Min Governor Speed Setpoint setting, it cannot be varied below this setting again unless the Idle/Rated ramp-to-Idle command is selected or a Controlled Stop is selected.
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Once turbine speed is equal to or greater than the Min Governor Speed Setpoint setting, the speed setpoint may be adjusted through discrete raise and lower commands. When a raise or lower speed command is issued, the setpoint moves at the programmed Speed Setpoint Slow Rate. If a speed raise/lower command is selected for longer than three seconds, the speed setpoint will then move at the fast rate which is three times the speed setpoint slow rate. The speed setpoint slow rate, fast rate delay, and fast rate can all be adjusted in the Service mode. The shortest length of time a setpoint will move for an accepted raise or lower command is 40 milliseconds (120 milliseconds for a Modbus command). If the speed setpoint slow rate is programmed for 10 rpm/sec, the smallest increment it will move is 0.4 rpm (1.2 rpm for Modbus). The speed setpoint may be set to a specific level, by directly entering a setpoint value through the 505 keypad or Modbus communications. To enter a specific setpoint from the 505 keypad, press the SPEED key to view the speed control screen, press the ENTER key, enter the setpoint level desired, then press the ENTER key again. If a valid number was entered, the setting will be accepted and the Speed setpoint will ramp to the entered setpoint level. If an invalid number is entered the setting will not be accepted and the 505s screen will momentarily display a value out-of-range message. When a valid setpoint value is entered, the setpoint will ramp at the speed setpoint slow rate to the newly entered setpoint value. This Entered rate is tunable through the Service mode. When using the ENTER key from the front panel keypad, the 505 checks the validity of the new entered setpoint. The speed setpoint must be below the maximum governor setting and above the idle setting and not within a critical speed avoidance band. Once the speed setpoint is above the minimum governor setting, the setpoint cannot be lowered below minimum governor. Also, if the unit is driving a generator and the unit is on-line, the speed setpoint cannot be set below the minimum load setting. The minimum load setting is defaulted to 5 rpm above the isochronous speed setpoint (changeable in the Service Mode). The speed setpoint can also be directly entered from either of the Modbus links, however, the allowed range is between the minimum governor and the maximum governor speed settings. The allowed setpoint range is limited to between the minimum load and the maximum governor settings if the unit is driving a generator and the unit is on-line.
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When the 505 is configured for a generator application, a special speed setpoint rate (Sync Window Rate) is used to increase setpoint resolution around synchronous speed. This allows for tighter setpoint control to accommodate synchronizing manually or by an automatic synchronizer which interfaces to the 505 discretely. This Sync Window Rate is defaulted to two rpm/sec and is only used when the generator breaker is open and the speed setpoint is within 10 rpm of rated speed. Both the synchronizing rate and the synchronizing window are tunable in the Service mode. When configured for generator applications a Minimum Load setpoint is used by the 505 to reduce the chance of reverse powering a unit upon closing the generator breaker. With the utility tie breaker closed, when a generator breaker closed indication is received, the Speed setpoint is stepped to the Minimum Load setting. The Minimum Load setting is defaulted to 3% (changeable in the Service Mode). To disable the use of the Minimum Load Setpoint, configure the Use Min Load setting (under the Service modes BREAKER LOGIC header) to No. See Chapter 6 for a list of all speed setpoint related Modbus parameters.
Frequency Arm/Disarm
The Frequency Arm/Disarm feature can be used only when loadsharing is not being performed, to allow multiple units to operate on the same isolated bus. With this feature, one unit on a multiple unit isolated bus controls frequency and the other units operate in a unit-load mode. The unit controlling frequency is referred to as the Swing Machine because its load will swing (vary) depending on the load of the plant. Caution should be taken with this configuration to not overload or reverse power the Swing Machine. This feature, when programmed, allows an operator to Arm or Disarm a units Frequency control mode while it is in operation. When Armed, a unit will switch to Frequency control if the plant-to-utility tie breaker opens. When Disarmed, a unit will stay in a unit-load control mode when the plant-to-utility tie breaker opens. To use this feature, the programs Use Freq Arm/Disarm setting must be set to Yes, the Sync/Load Sharing mode cannot be programmed, and a discrete command must programmed. The Frequency Arm/Disarm mode can be selected from a programmed contact input, Function key, or Modbus command. When the programmed contact input is closed the units Frequency control mode is Armed. When the programmed contact input is open the units Frequency control mode is Disarmed. Depending on a units size, health, and running status, an operator may select which unit is designated as the plant Frequency control unit if or when the plantto-utility tie breaker opens. Frequency control can be Armed at any time, but it will only go into control when the generator breaker is closed and the utility tie breaker is open.
CAUTION
Only one unit at a time should be have its Frequency control mode Armed. If multiple units try to control plant frequency at the same time they may fight and cause system instability, with the potential of damage to the equipment due to overloading or reverse powering a machine.
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If the Use Freq Arm/Disarm setting is set to No, Frequency control is always Armed and the unit will go into Frequency control when the utility tie contact is open. If the programs Use Freq Arm/Disarm setting is set to Yes then Frequency control must first be armed before the unit will switch into Frequency control when the utility tie contact is open.
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The Remote Speed Setpoint (RSS) range is determined by the programmed Analog inputs 4 mA and 20 mA settings. The Remote Speed Setpoint range is tunable in the Service mode (under REMOTE SPEED SETTINGS), but cannot control outside of the min governor and max governor speed setpoint values. Since RSS is a secondary speed setting function, the Speed PID must be incontrol of the 505s LSS bus to allow the RSS to position the actuator. When configured as a generator application, the RSS will not take control unless both breakers are closed and the speed PID is in control. When not configured as a generator application, turbine speed must reach min governor before the RSS can take control. The Cascade and Auxiliary (if configured to be enabled/disabled) controls are automatically disabled if RSS is enabled. The Remote Speed Setpoint may be enabled or disabled from the 505 keypad, external contact or Modbus. The last command given from any of these three sources dictates the enabled/disabled state. It does not matter whether the last command was given from the keypad or other devices. A contact input can be programmed to perform as an external Remote Speed Setpoint Enable function. When this programmed contact is open the RSS is disabled, and when it is closed the RSS is enabled. The contact can be either open or closed when trip condition is cleared. If the contact is open it must be closed to enable the RSS. If the contact is closed it must be opened and reclosed to enable the RSS function. If the milliamp signal to the Remote Speed setpoint input is out of range (below 2 mA or above 22 mA) an alarm will occur and the Remote Speed setpoint will be inhibited until the input signal is corrected and the alarm is cleared.
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Synchronization
Automatic generator synchronization can be performed through a Woodward Digital Synchronizer & Load Control (DSLC). The DSLC connects to a 505 analog input to bias the 505s speed setpoint directly to vary generator speed, frequency and phase. Optionally the DSLC can interface with the unit voltage regulator to match system voltage across a generator breaker. When the 505 is configured for a Generator application, a special speed setpoint rate (Sync Window Rate) is used to increase setpoint resolution around synchronous speed. This allows for tighter setpoint control to accommodate synchronizing manually or by an automatic synchronizer which interfaces to the 505 discretely. This Sync rate is defaulted to two rpm/sec and is only adjustable through the 505s Service mode. This rate is only used when the generator breaker is open the speed setpoint is within +10 rpm of rated speed (also tunable through the Service mode). The DSLC can be used as a synchronizer only or as a synchronizer and load control. When the DSLC is used as a synchronizer only, the 505 must be configured to accept the DSLCs analog Speed Bias signal and have this input enabled. A Sync Enable contact input or function key (F3 or F4) can be programmed to enable the 505s synchronizing input when synchronization is desired. The Sync Enable command becomes disabled when the generator breaker closes, however, it may re-enabled again to allow the DSLC to perform tie breaker synchronizations. To re-enable this input the Sync Enable contact must be opened and re-closed. Typically a double pole single throw (DPST) switch is used on a sites synchronizer control panel to select automatic synchronizing by enabling both the DSLC sync mode and 505 analog input at the same time. To configure the 505 to utilize a DSLC for generator synchronization only, program the Synchronizing input function to the ANALOG INPUT #6 setting and program the Sync Enable function to a CONTACT INPUT X setting. Analog Input #6 is isolated and is the only input directly compatible with the DSLCs output signal. The Synchronizing input function has preset range and gain settings that are tunable only in the Service mode. Thus the 4 mA and 20 mA Program Mode settings for the Synchronizing input are irrelevant and are not used by the functions operation. See Volume #2 of this manual or Woodward manual 02007 for more information on applying the DSLC. When programming a Function Key (F3 or F4), instead of a contact input, to enable the 505s analog Synchronizing input, a 505 relay output can also be programmed to select a DSLCs synchronizing mode. To configure the 505 for this functionality, program the Sync Enable function to a FX KEY PERFORMS setting, and the Sync Enabled function to a RELAY X ENERGIZES ON setting.
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When the 505 is programmed to use the DSLC for Synchronization, the RMT key can also be used to access and enable the Synchronizing function and monitor all synchronization mode messages. See Chapter 5 for information on how to enable this function through the RMT key. By pressing the RMT key and scrolling up or down through the RMT screens, the following synchronizing mode messages can be viewed: DisabledThe Synchronizing Input is disabled and will have no effect on the Speed setpoint. EnabledThe Synchronizing Input has been enabled. In ControlThe Synchronizing Input is biasing the Speed setpoint. InhibitedThe Synchronizing Input is inhibited and cannot be enabled. input signal is failed, both the utility tie and generator breakers are closed, the turbine is shut down, a controlled shutdown is being per-formed, or synchronizing control is not programmed.
Synchronizing/Loadsharing
A Woodward Digital Synchronizer & Load Control (DSLC) is used with a 505 to allow automatic generator synchronization to a bus and the sharing of load with other units (using DSLCs on the same bus). The Woodward DSLC is a microprocessor based generator load control designed for use on three-phase AC generators with Woodward speed controls and automatic voltage regulators. A DSLC with VAR/Power Factor control, allows all units with DSLCs to reactive load share as well as real power load share. The DSLC senses unit load through generator PTs & CTs and system load through the DSLC LON network (a combination of all units on the network). The DSLC uses a digital Echelon Network (LON) to communicate with other DSLCs on the same bus. When used as a synchronizer and load control, the DSLC performs automatic synchronization and controls unit load based on an internal base-load setting, a system average load setting, a process loops control setting, or a Master Synchronizer & Load Controls (MSLC) demand setting. After synchronization, unit load can be controlled by the DSLC through the Sync/Load Share input or by the 505s internal speed/load setpoint. The Utility Tie Breaker Contact is used to select unit load control through the DSLC or through the 505s internal load setpoint. When the 505s internal load control is selected (utility tie contact closed), the Speed PID setpoint is used to control unit load. Optionally the Cascade or Auxiliary control modes may be used to set unit load based on another system parameter. The DSLC interfaces to the 505 via its Speed Bias signal. To configure the 505 to utilize a DSLC for generator synchronizing and load sharing, program the Sync/Load Share input function to the Analog Input #6 setting and program the Sync/Ld Share Enable function to a Contact Input #X setting. Analog Input #6 is isolated, and the only input directly compatible with the DSLCs output signal. The Sync/Ld Share input function has preset range and gain settings that are tunable only in the Service mode (see Volume 2). Thus the 4 mA and 20 mA Program Mode settings for the Synchronizing input are irrelevant and are not used by the functions operation. A combination of the Utility Tie Breaker contact, Generator Breaker contact, and Sync/Ld Share Enable contact define the state of the 505s synchronizing and loadsharing operating modes (See Table 3-2).
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The Utility Tie breaker contact input is used to enable and disable Load Sharing when the generator breaker is closed. If the Utility Tie contact is open, loadsharing is enabled, and the 505s internal Speed PID droop, Cascade, and Auxiliary modes are disabled (as defaulted in Service mode). If the Utility Tie contact is closed loadsharing is disabled and the 505s Speed PID droop, Cascade, and Auxiliary modes are enabled, if used. The Generator Breaker contact input is used in conjunction with the utility tie contact to activate loadsharing. The Sync/Ld Share Enable contact input option is used to enable the Sync/Load Share analog input before the generator breaker is closed. Optionally a Function Key (F3 or F4) can be programmed to enable the 505s Sync/Load Share analog input instead of an external contact. This discrete enable/disable function is ignored after the generator breaker is closed, and must be reselected after the generator breaker opens. Typically a double pole single throw (DPST) switch is used on a sites synchronizer control panel to select automatic synchronizing by enabling both the DSLC sync mode and 505 analog input at the same time.
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Speed Control Mode Cascade or Auxiliary (if used) Speed, Off-Line not active Dynamics Unit Load Control, Onactive Line Dynamics Speed, Off-Line not active Dynamics Synchronizing Off-Line not active Dynamics Load Sharing, Off- Line not active dynamics
When programming a Function Key (F3 or F4) instead of a contact input to enable the 505s analog Sync/Load Share input, a 505 relay output, can be also be programmed to select a DSLCs synchronizing mode. To configure the 505 for this functionality, program the Sync/Ld Share Enable function to a FX KEY PERFORMS setting, and the Sync/Ld Share Enabled function to a RELAY X ENERGIZES ON setting. When the 505 is programmed to use the DSLC for Synchronization and Load Sharing, the RMT key can be used to access and enable the Sync/Load Share function and monitor all function mode messages. See Chapter 5 for information on how to enable this function through the RMT key. By pressing the RMT key and scrolling up or down through the RMT screens, the following Sync/Load Share mode messages can be viewed: DisabledThe Sync/Load Share Input is disabled and will have no effect on the Speed setpoint. EnabledThe Sync/Load Share Input has been enabled. In ControlThe Sync/Load Share Input is biasing the Speed setpoint. InhibitedThe Sync/Load Share Input cannot be enabled; the input signal is failed, the turbine is shut down, a controlled shutdown is being performed, or the sync/load share feature is not programmed. All pertinent synchronizing and loadsharing parameters are available through the Modbus links. See Chapter 6 for a complete listing of Modbus parameters.
Cascade Control
The Cascade control can be configured to control any system process, related to or affected by turbine speed or load. Typically this controller is configured and used as a turbine inlet or exhaust pressure controller. Cascade control is a PID controller that is cascaded with the Speed PID. The Cascade PID compares a 420 mA process signal with an internal setpoint to directly position the speed setpoint, thus changing turbine speed or load until the process signal and setpoint match. By Cascading two PIDs in this fashion, a bumpless transfer between the two controlling parameters can be performed. When enabled, the Cascade PID can move the speed setpoint at a variable rate up to the Max Speed Setpoint Rate setting (programmed under the CASCADE CONTROL header).
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Since Cascade is a secondary speed setting function, the Speed PID must be in control of the 505s LSS bus in order for Cascade to take control. When the 505 is configured for a generator application, both the utility tie and generator breakers must be closed, before the Cascade PID can begin controlling a process. Cascade control may be enabled and disabled from the 505 keypad, a contact input, or Modbus communications. The last command given from any of these three sources dictates the Cascade PIDs control state. If a contact input is programmed to function as a Cascade Enable contact, when the contact is open Cascade control is disabled, and when it is closed Cascade control is enabled. This contact can either be open or closed when a trip condition is cleared. If the contact is open it must be closed to enable Cascade control. If the contact is closed it must be opened and re-closed to enable Cascade control.
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Cascade control is automatically disabled on a shutdown condition, and must be re-enabled after a successful system startup. Cascade control is disabled if Remote Speed Setpoint is used and enabled. Should another parameter on the LSS bus take control of governor valve position from the Speed PID, Cascade control will stay active, and begin controlling again when the Speed PID is the lowest parameter on the LSS bus again. All pertinent cascade control parameters are available through the Modbus links, refer to Chapter 6 for a complete listing of Modbus parameters.
Cascade Dynamics
The Cascade PID control uses its own set of dynamic settings. These values are programmable and may be tuned at any time. Refer to the PID Dynamic Adjustments section in this manual.
Cascade Setpoint
The Cascade setpoint can be adjusted from the 505 keypad, external contacts, Modbus commands, or through a 420 mA analog input. A specific setting can also be directly entered from the 505 keypad or through Modbus commands. The Cascade setpoint range must be defined in the program mode. Program settings Min Cascade Setpoint and Max Cascade Setpoint define the range of the Cascade setpoint and control.
NOTE
Cascade setpoint raise/lower contact inputs act as speed setpoint raise/lower contacts when Cascade is not active or in control. This allows a single set of contacts (one SPDT switch) to control the Speed setpoint when the generator breaker is open, the load setpoint when paralleled to a utility, and the Cascade setpoint when enabled. Alternatively, a second set of contacts (speed raise and lower) could be used to independently control the speed and load setpoints.
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When a raise or lower Cascade Setpoint command is issued, the setpoint moves at the programmed Casc Setpt Rate setting. If a Cascade raise or lower command is selected for longer than three seconds, the Cascade setpoint will move at the fast rate which is three times the cascade setpoint rate. The Cascade setpoint rate, fast rate delay, and fast rate can all be adjusted in the Service mode. The shortest length of time a setpoint will move for an accepted raise or lower command is 40 milliseconds (120 milliseconds for a Modbus command). If the Cascade setpoint slow rate is programmed for 10 psi/sec, the smallest increment it will move is 0.4 psi (1.2 psi for Modbus). A specific setpoint may also be directly entered from the 505 keypad or through Modbus communications. When this is performed, the setpoint will ramp at the Casc Setpt Rate (as defaulted in Service mode). To enter a specific setpoint from the 505 keypad, press the CAS key to view the Cascade control screen, press the ENTER key, enter the setpoint level desired, then press the ENTER key again. If a valid number was entered, equal-to or between the min and max setpoint settings, the setting will be accepted and the Cascade setpoint will ramp to the entered setpoint level. If an invalid number is entered, the setting will not be accepted and the 505s screen will momentarily display a value out-ofrange message. When a valid setpoint value is entered, the setpoint will ramp at the Cascade Setpoint Rate to the newly entered setpoint value. This Entered rate is tunable through the Service mode. Refer to Volume 2 of this manual for information on which programmed settings are tunable through the 505s Service mode. Service mode values can be tuned/adjusted while the 505 is shutdown or in the RUN mode.
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Cascade Droop
When sharing control of a parameter with another external controller, the Cascade PID can also receive a programmable DROOP feedback signal for control loop stability. This feedback signal is a percentage of the Cascade PIDs output. By including this second parameter into the control loop, the Cascade PID becomes satisfied, and does not fight with the other external controller over the shared parameter. If Cascade droop is used, the Cascade input signal will not match the Cascade setpoint when in control. The difference will depend on the amount (%) of droop programmed and the output of the Cascade PID. The Droop value fed back to the Cascade PID is equal to the following defaulted settings: PID OUTPUT % x CASCADE DROOP % x MAX CASC SETPOINT x 0.0001 Where the CASCADE DROOP % and MAX CASC SETPOINT values are set in the Program Mode and the PID output % is determined by the Cascade demand. Example: 25% x 5% x 600 psi x 0.0001 = 7.5 psi Refer to Volume 2 of this manual for information on related Service mode tunables.
Invert Cascade
Depending on the control action required, the Cascade input signal can be inverted. If a decrease in inlet governor valve position is required to increase the Cascade process signal, program the INVERT CASCADE INPUT setting to YES. An example of this required control action would be when the Cascade PID is configured to control turbine inlet steam pressure. To increase turbine inlet steam pressure, the inlet control valve position must be decreased.
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If the milliamp signal to the Remote Cascade setpoint input is out of range (below 2 mA or above 22 mA) an alarm will occur and the Remote Cascade setpoint will be inhibited until the input signal is corrected and the alarm is cleared. Depending on configuration and system conditions, the Remote Cascade Setpoint may be in one of the following states (505 front panel screen messages): DisabledThe Remote Setpoint function is not enabled and will have no effect on the Cascade setpoint. EnabledThe Remote Setpoint has been enabled but cascade control is not active. The breakers are not closed, speed < min gov, or cascade has not taken control. ActiveThe Remote Setpoint has been enabled but Cascade is not in control. Cascade has been enabled and the Remote Cascade setpoint is in control of the setpoint but the Speed PID is not in control of the LSS bus. In ControlCascade is in control of the LSS bus (via the Speed PID) and the Remote Cascade Setpoint is positioning the Cascade setpoint. InhibitedRemote Setpoint cannot be enabled; input signal is failed, Cascade input signal is failed, a controlled stop is selected, the unit is shut down, or the remote cascade control is not programmed. When enabled, the Remote Cascade setpoint may not match the Cascade setpoint. In this case, the Cascade setpoint will ramp to the Remote Cascade setpoint at the programmed Casc Setpt Rate setting (as defaulted in the Service mode). Once in control, the fastest the Remote Cascade setpoint will adjust the Cascade setpoint is at the programmed Rmt Cascade Max Rate setting. If the Rmt Cascade Max Rate was set at 10 and the Remote Cascade setpoint analog input instantly moved from 0 units to 1000 units, the Remote Cascade setpoint will move to 1000 units at 10 units/sec).
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When both Remote Cascade Enable and Cascade Control Enable commands are programmed, each function is enabled by its respective command selection. If Remote Cascade Enable is selected, only the Remote Cascade Setpoint will be enabled. If Cascade Control Enable is selected, only Cascade control will be enabled. If Remote Cascade Disable is selected, only the Remote Cascade Setpoint will be disabled. If Cascade Control Disable is selected, both Remote Cascade control and Cascade control will be disabled. However, if before the Cascade PID was In-control, a Cascade disabled command is given, only Cascade control will be disabled. If no external contact input or function keys are programmed for the Enable commands, Cascade Control and Remote Cascade Control must be enabled from either the front panel keypad or from Modbus. Since the front panel and Modbus provide both Remote Cascade Enable and Cascade Control Enable commands, they will operate in the same manner as both enables programmed. Refer to Volume 2 of this manual for information on related Service mode tunables. All pertinent Remote Cascade control parameters are available through the Modbus links. See Chapter 6 for a complete listing of Modbus parameters.
Auxiliary Control
The Auxiliary PID controller can be used to limit or control generator power, plant import/export power, turbine inlet pressure, turbine exhaust pressure, pump/compressor discharge pressure, or any other auxiliary parameters, directly related to turbine speed/load. The Auxiliary input is a 4 to 20 mA current signal. The PID control amplifier compares this input signal with the Auxiliary setpoint to produce a control output to the digital LSS (low-signal select) bus. The LSS bus sends the lowest signal to the actuator driver circuitry.
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Depending on the configuration and system conditions, the Auxiliary PID may be in one of the following states (505 front panel screen messages): Auxiliary is DisabledAuxiliary is disabled and will have no effect on the LSS bus. Auxiliary is EnabledAuxiliary has been enabled but the generator and utility tie breaker permissives have not been met (generator applications only). Aux Active/Not in CtrlAuxiliary has been enabled, permissives met, but is not in control of the LSS bus. Aux Active w/Rmt SetptAuxiliary has been enabled but is not in control of the LSS bus and the remote Auxiliary input is controlling the setpoint. Auxiliary in ControlAuxiliary is in control of the LSS bus. Aux Control w/Rmt SetptAuxiliary is in control of the LSS bus and the remote Auxiliary analog input is in control of the setpoint. Auxiliary is InhibitedAuxiliary cannot be enabled; input signal is failed, 505 is in Frequency Control, controlled shutdown is selected, unit is shut down or Auxiliary control is not programmed. For generator applications, Auxiliary control can be configured to be disabled when the generator and/or utility tie breakers are open. Program settings TIEBKR OPEN AUX DSBL and GENBKR OPEN AUX DSBL may be configured to deactivate Auxiliary control depending on system breaker positions. When both settings are programmed NO, the Auxiliary control will always stay active. If the unit is not configured for a generator application, the utility tie and generator breaker inputs do not affect Auxiliary control status, and the controller will be active at all times (capable of being enabled). Auxiliary control may be enabled from the 505 keypad, remote contacts, or Modbus communications. The last command given from any of these three sources dictates which state the Auxiliary control is in. If an external Auxiliary Enable contact is programmed, disable is selected when the contact is open and enable is selected when it is closed. The contact can be either open or closed when a trip condition is cleared. If the contact is open it must be closed to enable. If the contact is closed it must be opened and re-closed to enable. When configured as enable/disable controller, the Auxiliary control will automatically be disabled upon a shutdown condition. Auxiliary control will be disabled and inhibited when the 505 is in frequency control. If the Auxiliary milliamp input signal is out of range (below 2 mA or above 22 mA) an alarm will occur and Auxiliary control will be inhibited until the input signal is corrected and the alarm is cleared. Optionally the unit can be programmed to issue a shutdown on a loss of the Auxiliary input signal.
Auxiliary Dynamics
The Auxiliary PID control uses its own set of dynamic settings. These values are programmable and may be tuned at any time. Refer to the PID Dynamic Adjustments section in this manual.
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Auxiliary Droop
When sharing control of a parameter with another external controller, the Auxiliary control amplifier can also receive a programmable DROOP feedback signal for control loop stability. This feedback signal is a percentage of the LSS bus (control valve position). By including this second parameter into the control loop, the Auxiliary PID becomes satisfied, and does not fight with the other external controller over the shared parameter. The Droop % fed back to the Auxiliary PID is equal to the following defaulted settings: LSS BUS OUTPUT % x AUXILIARY DROOP % x MAX AUX SETPOINT x 0.0001 Example: 25% x 5% x 600 psi x 0.0001 = 7.5 psi Where the AUXILIARY DROOP % and MAX AUX SETPOINT values are set in the Program Mode and the LSS bus output % is determined by the Auxiliary demand.
Auxiliary Setpoint
The Auxiliary setpoint can be adjusted from the 505 keypad, external contacts, Modbus commands, or through a 420 mA analog input. A specific setting can also be directly entered from the 505 keypad or through Modbus commands. The Auxiliary setpoint range must be defined in the program mode. Program settings Min Aux Setpoint and Max Aux Setpoint define the range of the Auxiliary setpoint and control. When a raise or lower Auxiliary Setpoint command is issued, the setpoint moves at the programmed Aux Setpt Rate setting. If a Auxiliary raise or lower command is selected for longer than three seconds, the Auxiliary setpoint will move at three times at the fast rate which is three times the Auxiliary setpoint rate. The Auxiliary setpoint rate, fast rate delay, and fast rate can all be adjusted in the Service mode.
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The shortest length of time a setpoint will move for an accepted raise or lower command is 40 milliseconds (120 milliseconds for a Modbus command). If the Cascade setpoint slow rate is programmed for 10 psi/sec, the smallest increment it will move is 0.4 psi (1.2 psi for Modbus). A specific setpoint may also be directly entered from the 505 keypad or through Modbus communications. When this is performed, the setpoint will ramp at the Aux Setpt Rate (as defaulted in Service mode). To enter a specific setpoint from the 505 keypad, press the AUX key to view the Auxiliary control screen, press the ENTER key, enter the setpoint level desired, then press the ENTER key again. If a valid number was entered, equal-to or between the min and max setpoint settings, the setting will be accepted and the Auxiliary setpoint will ramp to the entered setpoint level. If an invalid number is entered, the setting will not be accepted and the 505s screen will momentarily display a value out-ofrange message. When a valid setpoint value is entered, the setpoint will ramp at the Auxiliary Setpoint Rate to the newly entered setpoint value. This Entered rate is tunable through the Service mode. Refer to Volume 2 of this manual for further information on Service mode and online tunables. All pertinent auxiliary control parameters are available through the Modbus links. See Chapter 6 for a complete listing of Modbus parameters.
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In ControlThe Remote Setpoint is in control of the Auxiliary setpoint, and the Auxiliary PID is in control of the LSS bus. InhibitedRemote Setpoint cannot be enabled; Remote Setpoint input signal is failed, Auxiliary control is Inhibited, or Remote Auxiliary Setpoint is not programmed.
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Valve Limiter
The valve limiter, limits the actuator output signal (governor valve position) to aid in starting up and shutting down the turbine. The output of the valve limiter is Low-Signal-Selected with the output of the Speed and Auxiliary PIDs. The PID or limiter asking for the lowest valve position will control valve position. Thus, the valve limiter, limits the maximum valve position. The valve limiter can also be used to trouble shoot system dynamics problems. If it is believed that the 505 is the source of system instability, the valve limiter can be positioned to manually take control of the valve position. Care should be taken when using the valve limiter in this fashion, so as to not allow the system to reach a dangerous operating point. The valve limiter level is adjusted through the 505 keypad, contact input, or through Modbus communications. When raise or lower commands are received, the limiter ramps up or down, at the VALVE LIMITER RATE. The maximum the limiter can increase is 100%. The Valve Limiter Rate and Max Valve position settings can be adjusted in the Service mode. The shortest length of time a setpoint will move for an accepted raise or lower command is 40 milliseconds (120 milliseconds for a Modbus command). If the Valve limiter slow rate is programmed for 10 %/sec, the smallest increment it will move is 0.4 % (.2 % for a Modbus command). A specific setpoint may also be directly entered from the 505 keypad or through Modbus communications. When this is performed, the setpoint will ramp at the Valve Limiter Rate (as defaulted in Service mode). To enter a specific setpoint from the 505 keypad, press the LMTR key to view the Valve Limiter screen, press the ENTER key, enter the setpoint level desired, then press the ENTER key again. If a valid number was entered, equal-to or between the min and max setpoint settings, the setting will be accepted and the Valve Limiter will ramp to the entered level. If an invalid number is entered, the setting will not be accepted and the 505s screen will momentarily display a value out-of-range message. When a valid setpoint value is entered, the setpoint will ramp at the Valve Limiter Rate to the newly entered setpoint value. This Entered rate is tunable through the Service mode. Refer to Volume 2 of this manual for further information on Service mode and online tunables. All pertinent valve limiter parameters are available through the Modbus links. See Chapter 6 for a complete listing of Modbus parameters.
Emergency Shutdown
When an Emergency Shutdown condition occurs, the actuator output signal is stepped to zero milliamps, the Shutdown relay de-energizes, and the shutdown cause (first shutdown condition sensed) is displayed on the 505s front panel. Pressing the scroll down key from this screen will reveal any additional shutdown conditions that were sensed. See Chapter 5 for a detailed list of the possible shutdown (Trip) conditions.
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Up to five Emergency Shutdown inputs (contact inputs) can be programmed to allow the 505 to indicate the cause of an emergency shutdown. By wiring trip conditions directly into the 505, instead of a trip string, the 505 can pass a trip signal directly to its output relay (to trip the T&T valve), and also indicate the first trip condition sensed. The 505s total throughput time is 20 milliseconds (worse case). All trip conditions are indicated through the 505s front panel, and Modbus communications. The cause of the last trip can also be seen by pressing the CONT key, then pressing the scroll down key. The last trip indication, is latched-in and can be viewed at any time after a trip and before the next trip condition is latched in. Once latched-in the last trip indication cannot be reset. This allows an operator to confirm what the trip condition was hours or days after the unit has been reset and restarted. In addition to the dedicated Shutdown relay, the other programmable relays may be configured as Shutdown condition or Trip relays. The Shutdown Condition relay may be programmed to indicate a shutdown condition on a remote panel or to a plant DCS. The Shutdown Indication relay is normally de-energized. This relay will energize upon any shutdown condition and stay energized until all trips have been cleared. The Reset Clears Trip function has no effect on the programmable Shutdown Indication relay. When programmed as a Trip relay, the respective relay will function like the dedicated Shutdown relay (normally energized and de-energizes on a shutdown) to indicate the position of the dedicated Shutdown relay.
Controlled Shutdown
The 505s Controlled Shutdown function is used to stop the turbine in a controlled manner, as opposed to an Emergency Trip. When a STOP command (controlled shutdown) is issued the following sequence is performed: 1. All control PIDs and functions are disabled except the Speed PID controller 2. The Speed Setpoint is ramped to zero at the speed setpoint slow rate 3. After the Speed Setpoint reaches zero, the valve limiter is instantly stepped to zero 4. When the valve limiter reaches zero, the 505 executes a Shutdown command 5. A TRIP/Shutdown Complete message is displayed on the 505 front panel With the control in the run mode and the turbine turning, when the 505s STOP key is pressed, the control will display a message prompting the operator to verify the command (Manual Shutdown ?/Push YES or NO). At this point if the YES key is pressed the control will perform the controlled shutdown sequence explained above. Pushing the NO key will cause no change in the 505s operation, and the CONTROLLING PARAMETER screen will be displayed. This verification feature prevents an unwanted shutdown if the STOP key is accidentally pushed. A controlled shutdown can be initiated or aborted from the 505 front panel, a programmed contact input or either Modbus communication link. Verification is not required, if a controlled shutdown command is initiated by an programmed contact input or Modbus communication link.
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The controlled shutdown sequence can be aborted at any time. During a controlled shutdown sequence, by pressing the STOP key, the 505 will display a Manual Shutdown In Ctrl/Push NO to Disable message. Pressing the NO key from this screen will cause the shutdown sequence to be aborted, and the control to display a Manual Shutdown Stopped/Push YES to Continue message. At this point the shutdown sequence can be re-initiated when desired, or the unit can be brought back to a fully operational state. If an external contact is programmed to issue a controlled shutdown command, closing the contact will initiate the controlled shutdown sequence. The shutdown sequence will go through the same steps described above, with the exception that verification of the shutdown sequence is not needed. Opening the programmed contact will stop the sequence. The contact can be either open or closed when a trip condition is cleared. If the contact is open it must be closed to issue the command. If the contact is closed it must be opened and re-closed to issue the command. The Modbus initiated Control Shutdown Sequence requires two commands, one to start the sequence and the other to stop it. The speed sensor failure trip, generator breaker open trip, and tie breaker open trip commands are overridden when a controlled shutdown is initiated.
NOTE
This command can be disabled through the Service Mode, if desired (see Key Options). When disabled, the Controlled Stop feature is disabled from front panel, Modbus, and contact commands. See Chapter 5 of this Volume for all 505 service panel messages.
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There are two programmable relay options available to indicate overspeed status. One programmable relay option indicates an Overspeed Trip condition. The second relay option provides indication that an Overspeed Test is being performed. See Chapter 5 of this manual for a complete Overspeed Test Procedure. All pertinent overspeed test parameters are available through the Modbus links. See Chapter 6 for a complete listing of Modbus parameters.
Local/Remote Function
The 505s Local/Remote function allows an operator at the turbine skid or 505 to disable any remote command (from a remote Control Room) that may put the system in a unsafe condition. This function is typically used during a system startup or shutdown to allow only one operator to manipulate the 505 control modes and settings. The Local/Remote function must first be programmed before a Local or Remote mode can be selected by an operator. This function can be programmed under the OPERATING PARAMETERS BLOCK. If this function is not programmed all contact inputs and Modbus commands (when Modbus is programmed) are active at all times. If the Local/Remote function is programmed, Local and Remote modes can be selected through a programmed contact input, programmed function key (F3, F4), or Modbus command. When Local mode is selected, the 505 is defaulted to be operable from its front panel only. This mode disables all contact inputs and Modbus commands, with exceptions noted below: External trip Contact In (defaulted in program) External trip 2 Contact In (active at all times, if programmed) External trip 3 Contact In (active at all times, if programmed) External trip 4 Contact In (active at all times, if programmed) External trip 5 Contact In (active at all times, if programmed) Override MPU Fault Contact In (active at all times, if programmed) Frequency Arm/Disarm (active at all times, if programmed) Generator breaker Contact In (active at all times, if programmed) Utility tie breaker Contact In (active at all times, if programmed) Start permissive Contact In (active at all times, if programmed) Switched dynamics Contact In (active at all times, if programmed) Local/Remote Contact In (active at all times, if programmed) Local/Remote Modbus Command (active at all times, if Modbus programmed) Trip Command Modbus Command (active at all times, if Modbus programmed) When the Remote mode is selected the 505 can be operated through its front panel, contact inputs, and/or all Modbus commands. When using a contact input to select between Local and Remote modes, a closed contact input selects the Remote mode and an open contact input selects the Local mode. Optionally a relay can be programmed to indicate when Local mode is selected (energizes when the Local mode is selected). There is also indication of the Local/Remote mode selection through Modbus (address = true when the Remote mode is selected and false = when the Local mode is selected).
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The 505 is defaulted to only allow control operation though its front panel when the Local mode is selected. If desired, this defaulted functionality can be changed through the 505s Service mode. The 505 can be modified to also allow operation through contacts inputs, or Modbus port #1 or Modbus port #2 when the Local mode is selected. All pertinent local/remote control parameters are available through the Modbus links. See Chapter 6 for a complete listing of all Modbus parameters.
Function Keys
Function keys, F3 & F4 are located on the 505s front panel, and can be programmed independently to function as a control panel switch. These keys allow functions to be enabled and disabled from the 505s front panel, without requiring the use of an external switch. The following is a list of the programmable options for the function keys: Local/Remote Cascade Enable Idle/Rated Remote Cascade Setpoint Enable Halt Continue Auto Start Seq Auxiliary Enable Remote Speed Setpoint Enable Remote Auxiliary Setpoint Enable Sync Enable Relay Output Frequency Control Arm/Disarm A two step process is required to enable or disable any function. Pressing a programmed function key will cause the 505s service panel to display the current state of the function and prompt the operator to press the YES or NO keys to enable or disable the function. A functions prompt will change depending on the state of the function at that time. As an example, if the F3 key is programmed to allow an operator to enable and disable the 505s Remote Speed Setpoint, when the F3 key is pressed a (Push Yes to Enable/Rmt Spd Setpt Disabled) message will appear on the front panel display. Pressing YES will enable the Remote Speed Setpoint function and the message will change to (Push No to Disable/Rmt Spd Setpt In Control).
Relays
The 505 has eight relay outputs available. Two of these relays are dedicated; one for a system shutdown command from the 505 and one for alarm indication. The other six relays can be programmed for a variety of indications, and system functions. For fail-safe operation, the dedicated Shutdown relay is energized during normal system operation, and will de-energize when a shutdown occurs. The dedicated Alarm relay is normally de-energized. This relay will energize upon an alarm condition and stay energized until the alarm condition is cleared. Optionally this relay can be configured, through the 505s Service mode, to toggle on and off repeatedly when an alarm conditions has occurred. With this configuration if a reset command is given and the alarm condition still exists, the relay will stop toggling and stay energized. The relay will start toggling again, upon a new alarm condition. This option can be used to inform the operator when another alarm condition has occurred.
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Any of the other six relays can be programmed to function as a level switch or mode indication. When programmed as a level switch the relay will change state when the selected parameter reaches the programmed level (energizes when value is higher the programmed level). The following is a list of the 505s relay options for level indication: Speed Aux Setpoint Speed Setpoint Actuator Demand KW Input Actuator 1 Demand Sync/Load Share Input Actuator 2 Demand Cascade Input Valve Limiter Casc Setpoint First Stage Pressure Aux Input The present relay state (energized/de-energized) and relay configuration is indicated through both Modbus communication links. Relays not used as level switches can be programmed to indicate control states. Except for the Trip relay, when programmed to indicate a state or event, relay will energize upon the respective state or event occurring. The following is a list of options for relays if used to indicate a control mode or state: Shutdown Condition Sync Enabled Trip Relay (additional trip relay output) Sync or Load Share Enabled Alarm Condition Load Share Control Enabled 505 Control Status OK Casc Control Enabled Overspeed Trip Cascade Control Active Overspeed Test Enabled Remote Casc Setpt Enabled Speed PID in Control Remote Casc Setpt Active Remote Speed Setpt Enabled Aux Control Enabled Remote Speed Setpt Active Aux Control Active Underspeed Switch Auxiliary PID in Control Auto Start Sequence Halted Remote Aux Setpt Enabled On-Line PID Dynamics Mode Remote Aux Setpt Active Local Control Mode Valve Limiter in Control Frequency Control Armed F3 Key Selected Frequency Control F4 Key Selected Modbus Command
Relay Clarifications
The Shutdown Condition relay may be programmed to indicate a shutdown condition on a remote panel or to a plant DCS. The Shutdown Indication relay is normally de-energized. This relay will energize upon any shutdown condition and stay energized until all trips have been cleared. The RESET CLEARS TRIP function has no effect on the programmable Shutdown Indication relay. When programmed as a Trip relay, the respective relay will function like the dedicated Shutdown relay (normally energized and de-energizes on a shutdown) to indicate the position of the dedicated Shutdown relay. This relay output can be programmed to indicate a 505 initiated trip by setting the Ext trips in Trip Relay option to NO. Using this option, 505 trip annunciation will only occur if the 505 tripped the turbine and not annunciate when the other external devices shuts down the unit (external trips).
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The Alarm Condition relay may be programmed to indicate an alarm condition on a remote control panel or to a DCS. The Alarm Indication relay is normally deenergized. This relay will energize upon any alarm condition and stay energized until all alarms have been cleared. If the BLINK ALARMS option is YES the programmable Alarm Condition relay will toggle on and off repeatedly when an alarm condition has occurred. With this configuration if a reset command is given and the alarm condition still exists, the relay will stop toggling and stay energized. The 505 Control Status OK relay is normally energized, and will only de-energize if unit inlet power is lost, the 505s CPU fails, or the 505 is in the program mode. The Overspeed Test Enable relay will energize when an Overspeed Test is performed. This relay functions like the 505 OSPD keys LED (it repeatedly toggles on and off when turbine speed is above the turbine Overspeed trip setting). An Underspeed Switch function can be programmed to indicate a turbine underspeed or overpower condition. If the Underspeed option is configured, once turbine speed reaches a level above the minimum governor speed setting, then decreases 100 rpm below the minimum governor speed setting, the respective relay energizes (indicating an underspeed condition). The Underspeed setting is adjustable through the Service mode, under the Speed Values header. When the Sync Enabled function is programmed, the assigned relay energizes when a synchronize command is given. After the unit generator or utility tie breaker is closed this function becomes disabled and the relay de-energizes. The 505s Synchronization function can be used to synchronize across a generator breaker or utility tie breaker. When the Sync or Load Share Active function is programmed, the assigned relay energizes when a synchronizing or Load Sharing is active. When both the generator and utility tie breaker inputs are closed (Load Sharing not selected) this function becomes disabled and the relay de-energizes. When the (F3,F4) Key Selected function is programmed, the assigned relay energizes when the respective function key is pressed and an enable/disable command issued. This feature allows the 505s F3 and F4 function keys to be used as panel switches to select and/or enable system related functions (synchronizers). When the Modbus Command function is programmed, the assigned relay energizes when the respective Modbus command Turn On Modbus Relay X is issued, then de-energizes when the respective Modbus command Turn Off Modbus Relay X is issued. This feature allows a 505 relay to be driven directly from Modbus to control a system related function (synchronizing). In addition, the assigned relay can be momentarily energized using the Modbus command Momentarily Energize Modbus Relay X is issued (voltage raise/lower commands). Refer to Chapter 6 of this manual for more information on Modbus commands.
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The program cannot be changed or altered while the turbine is running, however, it can be accessed and all programmed values monitored. This minimizes the possibility of introducing step disturbances into the system. To monitor or review the program while in the run mode, simply press the PRGM key then step across or step down as necessary. If a wrong key is pressed the display will revert to the last screen displayed before entering the program mode or the screen designated to the key pressed.
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The touch keypad has several dual-function keys. Pushing any dual-function key in the Program Mode enters the appropriate numeric or yes/no value printed on the key. Pushing the key in the Run Mode enters the operating parameter printed on the key, unless the ENTER key has been pressed to enter a specific numeric setpoint value.
Manual 85017V1
The 505 program mode (configuration) may be accessed once the configuration check is complete and the turbine is not running. For safety reasons the program may be monitored only and no changes will be accepted if the turbine is running. By pressing the PRGM key and entering the password (1113) then pressing ENTER on the 505 keypad the SHUTDOWN CONTROL Y/N prompt will appear. If YES is pressed the 505 will issue a shutdown and the program mode will be accessed. If NO is pressed the 505 will revert to the Select Mode screen and the program mode will not have been accessed. All configuration (program mode) values and saved service mode changes are stored in the nonvolatile memory (EEPROMs) of the 505 control. If power is removed from the 505 all saved values will return once power is restored. No batteries or back up power is required.
CAUTION
The field-configured portion of the program will be zeroed out after factory repair. To prevent damage to your equipment, you must reconfigure the Program Mode before the unit is put back into service.
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Program Blocks
Figure 4-3 shows the 13 program columns. To program the control, simply step through the blocks as described above and configure the control features for the desired application. The first seven program columns must be programmed for every installation. The remaining six columns contain optional features which can be selected if desired. The 13 columns and their basic functions are described in detail below. Required Configuration Blocks: Turbine Start to configure start mode, idle/rated, and auto start sequence settings; Speed Control to configure MPU or PROX PROBE information and speed control dynamics settings; Speed Setpoint Values to configure speed setpoints, overspeed trip setpoint, remote speed setting control and critical speed avoidance bands; Operating Parameters to configure the unit for generator application and to use the local/remote function; Driver Configuration to configure driver outputs and, if not using driver 2, to use driver 2 for a 420 mA readout; Analog Inputs to configure analog input options; Contact Inputs to configure contact input options; Optional Configuration Blocks: Function Keys Auxiliary Control Cascade Control Readouts Relays Communications
to configure F3 and F4 function keys options; to configure auxiliary control information; to configure pressure, temperature control information; to configure analog readout options; to configure relay options; to configure Modbus communication options.
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Each of the program blocks are described in detail below. Figure 4-3 can be referred to for a graphical program block reference. After a column has been configured and the display is back at the top of the column, use the left or right arrow keys to select the next column to configure or check. All control program questions will be displayed on the top line of the display; all entries made will be displayed on the lower line of the display. At the beginning of each column the control will display the header, pushing the down arrow will access the column. The program blocks (Figure 4-3) contain information detailing each question and/or 505 program configuration option. Each question/option shows the default (dflt) value and the adjustable range of that parameter (shown in parentheses). In addition, any additional constraints on the configuration are shown in italics following the description. There is a program mode worksheet in the appendix of this manual that should be completed/filled-in and used as a guide for your particular application. This worksheet can also be used for future reference to document your application program.
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VALVE LIMITER RATE ( %/sec) dflt= 5.0 (0.1, 25) Enter the Valve Limiter Rate, in percent per second, followed by ENTER. This is the rate at which the valve limiter moves when RUN is selected or when the limiter setting is changed through open/close commands. When using a semiautomatic or automatic start, this setting should be very slow typically less than 2 %/sec. When using a manual start, this setting is less critical and can be left at the default of 5 %/sec. USE IDLE/RATED ? dflt= NO (Yes/No) Select YES followed by ENTER if this function is desired. If NO, skip to Use Auto Start Sequence. If YES is selected, the control will ramp from a programmable Idle speed to a programmable Rated speed setpoint when Rated is selected through keypad, Modbus or external switch. IDLE SETPT (rpm) dflt= 1000 (0.0, 20000) Enter the Idle Speed setpoint desired followed by the ENTER key. This is the lowest speed control setpoint when using the Idle/Rated function. RATED SETPT (rpm) dflt= 3600 (0.0, 20000) Enter the Rated Speed setpoint desired followed by the ENTER key. This is the speed control setpoint that the unit accelerates to when using the Idle/Rated function. (Must be greater than or equal to the Minimum Governor Speed Setting) IDLE/RATED SETPT RATE ( rpm/sec) dflt= 5.0 (0.01, 2000) Enter the Idle/Rated rate (rpm/second) followed by ENTER. This is the at which the speed setpoint moves between Idle and Rated speed setpoints when using the Idle/Rated commands. USE AUTO START SEQUENCE ? dflt= NO (Yes/No) Enter YES followed by ENTER if this function is desired. If NO is selected followed by ENTER, then the program will step to Reset Clears Trip Output question. If this function is programmed and RUN is selected, the 505 automatically accelerates the speed setpoint to a programmable low idle speed and holds for a programmable time then ramps to a programmable high idle speed and holds for a programmable time then ramps to programmable rated speed setpoint. The start sequence can be actuated or halted through the keypad, Modbus or external switch. COLD START ( > xx HRS ) dflt= 10 (0.0, 200) Enter the time in hours allowed after a trip before the cold start sequence curves are to be used followed by the ENTER key. If this much time has expired (or more) after a trip condition, then the control will use the cold start values. If less than this time has expired, the control will interpolate between the hot and cold start values to determine rates and hold times. HOT START ( < xx HRS) dflt= 1.0 (0.0, 200) Enter the maximum time allowed after a trip for the hot start sequence curves to be used followed by the ENTER key. If less than this time has expired after a trip condition, then the control will use the hot start values. (Must be less than or equal to the Cold Start Hours) LOW IDLE SETPT (rpm) dflt= 1000 (0.0, 20000) Enter the Low Idle Speed Setting followed by the ENTER key. This is the first hold speed when using the automatic start sequence. The speed setpoint will remain at this setting until the low idle delay/hold time has expired. LOW IDLE DELAY TIMECOLD (MINUTES) dflt= 1.0 (0.0, 500) Enter the cold start hold time desired at low idle followed by ENTER. This is the programmable time, in minutes, that the turbine will wait/hold at the low idle speed when a cold start is determined.
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LOW IDLE DELAY TIME- HOT (MINUTES) dflt= 1.0 (0.0, 500) Enter the hot start hold time at low idle followed by ENTER. This is the programmable time, in minutes/seconds, that the turbine will wait/hold at the low idle speed when a hot start is determined. If the turbine has been shutdown for longer than the Hot time but shorter than the Cold time, the control will interpolate between the Hot and Cold delays to determine the low idle hold time. (Must be less than or equal to the Low Idle DelayCold Setting) RATE TO HI IDLECOLD (rpm/sec) dflt= 5.0 (0.01, 500) Enter the cold start rate to high idle followed by ENTER. This is the programmable rate, in rpm per second, that the speed setpoint will accelerate at when moving to high idle when a cold start is determined. RATE TO HI IDLEHOT (rpm/sec) dflt= 5.0 (0.01, 500) Enter the hot start rate to high idle followed by ENTER. This is the programmable rate, in rpm per second, that the speed setpoint will accelerate at when moving to high idle when a hot start is determined. If the turbine has been shutdown for longer than the Hot time but shorter than the Cold time, the control will interpolate between the Hot and Cold rates to determine the acceleration rate to the hi idle setpoint. (Must be greater than or equal to the Rate to Hi IdleCold Setting HI IDLE SETPT (rpm) dflt= 2000 (0.0, 20000) Enter the Hi Idle Speed Setting followed by the ENTER key. This is the second hold speed when using the automatic start sequence. The speed setpoint will remain at this setting until the Hi Idle Delay/hold time has expired. (Must be greater than the Low Idle Setting) HI IDLE DELAY TIMECOLD (MINUTES) dflt= 1.0 (0.0, 500) Enter the cold start hold time desired at hi idle followed by ENTER. This is the programmable time, in minutes, that the turbine will wait/hold at the hi idle speed when a cold start is determined. HI IDLE DELAY TIMEHOT (MINUTES) dflt= 1.0 (0.0, 500) Enter the hot start hold time desired at hi idle followed by ENTER. This is the programmable time, in minutes, that the turbine will wait/hold at the hi idle speed when a hot start is determined. If the turbine has been shutdown for longer than the Hot time but shorter than the Cold time, the control will interpolate between the Hot and Cold delays to determine the hi idle hold time. (Must be less than or equal to the Hi Idle DelayCold Setting) RATE TO RATED SETPTCOLD (rpm/sec) dflt= 5.0 (0.01, 500) Enter the cold start rate to the rated speed setpoint followed by ENTER. This is the programmable rate, in rpm per second, that the speed setpoint will accelerate at when moving to rated when a cold start is determined. RATE TO RATED SETPTHOT (rpm/sec) dflt= 5.0 (0.01, 500) Enter the hot start rate to the rated speed setpoint followed by ENTER. This is the programmable rate, in rpm per second, that the speed setpoint will accelerate at when moving to rated when a hot start is determined. If the turbine has been shutdown for longer than the Hot time but shorter than the Cold time, the control will interpolate between the Hot and Cold rates to determine the acceleration rate to the rated setpoint. (Must be greater than or equal to the Rate to RatedCold Setting) RATED SETPT (rpm) dflt= 3600 (0.0, 20000) Enter the Rated Speed Setting followed by the ENTER key. This is the final speed setting when using the automatic start sequence. Once this speed setpoint is reached, the start sequence is complete. (Must be greater than or equal to the Minimum Governor Setting)
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AUTO HALT AT IDLE SETPTS? dflt= NO (Yes/No) Select YES followed by the ENTER key to automatically halt the auto start sequence at the idle setpoints. This feature would result in the unit automatically stopping/halting at the low idle setpoint and at the high idle setpoint. Also, if the unit is started and the speed is above the low idle setpoint, the sequence will be halted. Select NO to allow the control to perform its automatic start sequence routine without interruption. EXTERNAL TRIPS IN TRIP RELAY ? dflt= YES (Yes/No) Select YES followed by the ENTER key to allow the external trip input(s) to de- energize the Trip Relay output. When set to NO, an external trip contact input to the 505 will shut down the 505 control but will not de-energize the 505s trip relay output. RESET CLEARS TRIP OUTPUT ? dflt= NO (Yes/No) Select YES followed by the ENTER key to configure the Reset Clears Trip Relay output function. When set to YES, a Reset command will energize the trip relay output even when a trip condition is still sensed by the 505 typically due to one of the external trip inputs. Once reset, the unit will be Ready to Start as soon as all external trip inputs are closed. When NO, the trip relay output will be de-energized on a 505 trip and will not energize until all trips have cleared and a Reset command is given.
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OFF-LINE PROPORTIONAL GAIN dflt= 5.0 (0.0, 100) Enter the off-line PID proportional gain percentage followed by ENTER. This value is used to set speed/load control response when the Generator or Utility Tie breaker contacts are open (if the unit is a generator) or if the turbine speed is below minimum governor speed (if the unit is not a generator) or when the Select Dynamics function is used and the contact is open. This value can be changed in the Run Mode while the turbine is operating. A recommended starting value is 5%. OFF-LINE INTEGRAL GAIN dflt= 0.5 (0.01, 50) Enter the off-line PID integral gain percentage followed by ENTER. This value is used to set speed/load control response when the Generator or Utility Tie breaker contacts are open (if the unit is a generator) or if the turbine speed is below minimum governor speed (if the unit is not a generator) or when the Select Dynamics function is used and the contact is open. This value can be changed in the Run Mode while the turbine is operating. A recommended starting value is 0.5%. OFF-LINE DERIVATIVE RATIO dflt= 5.0 (0.01, 100) Enter the off-line PID derivative ratio followed by ENTER. This value is used to set speed/load control response when the Generator or Utility Tie breaker contacts are open (if the unit is a generator) or if the turbine speed is below minimum governor speed (if the unit is not a generator) or when the Select Dynamics function is used and the contact is open. This value can be changed in the Service Mode while the turbine is operating. A recommended starting value is 5% . ON-LINE PROPORTIONAL GAIN dflt= 5.0 (0.0, 100) Enter the on-line PID proportional gain percentage followed by ENTER. This value is used to set speed/load control response when the Generator and Utility Tie breaker contacts are closed (if the unit is a generator) or if the turbine speed is above minimum governor speed (if the unit is not a generator) or when the Select Dynamics function is used and the contact is closed. This value can be changed in the Run Mode while the turbine is operating. A recommended starting value is 5%. ON-LINE INTEGRAL GAIN dflt= 0.5 (0.01, 50) Enter the on-line PID integral gain percentage followed by ENTER. This value is used to set speed/load control response when the Generator and Utility Tie breaker contacts are closed (if the unit is a generator) or if the turbine speed is above minimum governor speed (if the unit is not a generator) or when the Select Dynamics function is used and the contact is closed. This value can be changed in the Run Mode while the turbine is operating. A recommended starting value is 0.5%. ON-LINE DERIVATIVE RATIO dflt= 5.0 (0.01,100) Enter the on-line PID derivative ratio followed by ENTER. This value is used to set speed/load control response when the Generator and Utility Tie breaker contacts are closed (if the unit is a generator) or if the turbine speed is above minimum governor speed (if the unit is not a generator) or when the Select Dynamics function is used and the contact is closed. This value can be changed in the Service Mode while the turbine is operating. A recommended starting value is 5% (see Chapter 5PID Dynamics Settings for more information).
Manual 85017V1
OVERSPEED TEST LIMIT (rpm) dflt= 1100 (0.0, 20000) Set the overspeed test limit (in rpm) followed by the ENTER key. This is the maximum speed setpoint the control will increase to when overspeed testing the unit. The setpoint can only be raised to this level when the overspeed test function is being performed. OVERSPEED TRIP LEVEL (rpm) dflt= 1000 (0.0, 20000) Set the 505s overspeed trip level (in rpm) followed by the ENTER key. This is the governor overspeed trip setpoint only and is not to be used as ultimate overspeed protection. (Must be less than the Overspeed Test Limit Setting) MAX GOVERNOR SPEED SETPOINT (rpm) dflt= 0.0 (0.0, 20000) Set the maximum governor control speed followed by the ENTER key. This is the normal governor operation upper limit. For turbine/generator applications, this value must be at least equal to [Rated Speed + (Droop % x Rated Speed)]. (Must be less than the Overspeed Trip Level Setting) MIN GOVERNOR SPEED SETPOINT (rpm) dflt= 0.0 (0.0, 20000) Set the minimum governor control speed followed by the ENTER key. This is the normal governor operation lower limit. (Must be less than the Maximum Governor Speed Setting) SPEED SETPOINT SLOW RATE (rpm/sec) dflt= 5.0 (0.01, 100) Enter the speed setpoint slow rate in rpm per second followed by the ENTER key. This the rate of speed change for normal operation. USE REMOTE SPEED SETPOINT ? dflt= NO (Yes/No) Set to YES followed by ENTER if using an analog input to set the Speed/Load Setpoint. RMT SPEED SETPT MAX RATE (rpm/sec) dflt= 50.0 (0.01, 500) Enter the Maximum Rate of speed change for remote speed setpoint operation followed by the ENTER key. USE CRITICAL SPEEDS ? dflt= NO (Yes/No) Set to YES followed by ENTER to use the critical speed avoidance logic. When set to YES, allows up to two critical speed avoidance bands to be programmed. Within the band, the speed setpoint cannot be stopped. These bands are used to protect the turbine and driven device from speeds that have inherently high vibration. (Must program either Idle/Rated or Auto Start Sequence to use critical speed avoidance. The lowest critical speed min must be greater than idle or low idle.) CRITICAL SPEED RATE (rpm/sec) dflt= 50.0 (0.1, 2000) Set the rate that the speed setpoint will move through the critical speed avoidance ranges (in rpm/second) followed by the ENTER key (Must be greater than the Speed Setpt Slow Rate Setting) CRITICAL SPEED 1 MAX (rpm) dflt= 1.0 (1.0, 20000) Set the upper limit of the critical speed avoidance band followed by the ENTER key. (Must be less than the Minimum Governor Speed Setting) CRITICAL SPEED 1 MIN (rpm) dflt= 1.0 (1.0, 20000) Set the lower limit of the critical speed avoidance band followed by the ENTER key. (Must be less than the Critical Speed 1 Max Setting) USE CRITICAL SPEED 2 ? dflt= NO (Yes/No) Select YES followed by the ENTER key to use the second critical speed avoidance band. CRITICAL SPEED 2 MAX (rpm) dflt= 1.0 (1.0, 20000) Set the upper limit of the critical speed avoidance band followed by the ENTER key. (Must be less than the Minimum Governor Speed Setting)
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CRITICAL SPEED 2 MIN (rpm) dflt= 1.0 (1.0, 20000) Set the lower limit of the critical speed avoidance band followed by the ENTER key. (Must be less than the Critical Speed 2 Max Setting)
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USE LOCAL/REMOTE? dflt= NO (Yes/No) Set to YES if using Local/Remote control logic followed by the ENTER key. If YES, permits the unit to go from REMOTE (Modbus, contact input and front panel) control to LOCAL (front panel) control only. If NO, all programmed inputs are active at all times. Refer to the Service Mode information in Volume 2 for additional settings on the Local/Remote function.
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USE ACTUATOR 2 AS A READOUT? dflt= NO (Yes/No) Select YES followed by ENTER to use the actuator output as an additional readout. When set to NO, the actuator #2 output is not used for anything. This option is available for customers who do not need two actuator drivers and would like an additional readout. ACTUATOR 2 READOUT IS: (must choose from list) Scroll through the option list by using the Adjust Up/Down Arrows or by selecting the NO key until the option desired appears, then press the YES or ENTER keys to select the option/function. OPTIONS FOR ACTUATOR 2 READOUT Actual Speed Rmt Cascade Setpt Speed Setpoint Auxiliary Input Remote Speed Setpt Auxiliary Setpoint Sync/Load Share Input Rmt Auxiliary Setpt KW Input Valve Limiter Setpoint Cascade Input Actuator 1 Readout Cascade Setpoint First Stage Press Input (The function that the readout uses must be programmed or an error message will occur. For example, to use the Cascade Setpoint readout, the Use Cascade function must be programmed) READOUT 4 mA VALUE (UNITS) dflt= 0.0 (-20000, 20000) Set the value (in engineering units) that corresponds to 4 milliamps (mA) on the analog output followed by the ENTER key. If the value on the display is correct, just select the ENTER key which will advance you to the next question. READOUT 20 mA VALUE (UNITS) dflt= 0.0 (-20000, 20000) Set the value (in engineering units) that corresponds to 20 milliamps (mA) on the analog output followed by the ENTER key. If the value on the display is correct, just select the ENTER key which will advance you to the next question. (Must be greater than the Readout 4 mA Value Setting)
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INPUT 14 mA VALUE (UNITS) dflt= 0.0 (-20000, 20000) Set the value (in engineering units) that corresponds to 4 milliamps (mA) on the analog input followed by the ENTER key. If the value on the display is correct, just select the ENTER key which will advance you to the next question. INPUT 120 mA VALUE (UNITS) dflt= 100 (-20000, 20000) Set the value (in engineering units) that corresponds to 20 milliamps (mA) on the analog input followed by the ENTER key. If the value on the display is correct, just select the ENTER key which will advance you to the next question. (Must be greater than the Input 4 mA Value Setting Analog Inputs # 2 through # 6 are entered following the same rules as described for Analog Input # 1.
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MIN AUX SETPOINT (UNITS) dflt= 0.0 (-20000, 20000) Set the min AUX setpoint followed by ENTER. This value is the minimum setpoint value that the auxiliary setpoint can be decreased/lowered to (lower limit of AUX setpoint). MAX AUX SETPOINT (UNITS) dflt= 100 (-20000, 20000) Set the max AUX setpoint followed by ENTER. This value is the maximum setpoint value that the auxiliary setpoint can be increased/raised to (upper limit of AUX setpoint). (Must be greater than the Min Aux Setpt Setting) AUX SETPOINT RATE (UNITS/sec) dflt= 5.0 (0.01, 1000) Set the AUX setpoint rate followed by ENTER. This value is the rate (in units per second) at which AUX setpoint moves when adjusted. USE AUX ENABLE? dflt= NO (Yes/No) Select YES followed by ENTER if using the Auxiliary control enable/disable feature. If YES, Aux will require an ENABLE command to enable Aux control. If NO, then the Auxiliary function will be enabled constantly and will act as a controlling limiter. An example of using Aux as a limiter is using Aux to limit the maximum KW load that the unit carries. The Aux PID is not normally in control of the valve output. But if the Aux (KW) input exceeds the setpoint, the Aux PID controller would decrease and take control of the valve until the KW level decreases below the maximum kW(Aux) setting. Alternatively, if the Aux enable is used, the Aux setpoint tracks the Aux input. When enabled, the Aux PID takes control of the valve and the speed setpoint tracks the speed/load of the unit for bumpless transfer between modes. SETPT INITIAL VALUE (UNITS) dflt= 0.0 (-20000, 20000) Set the setpoint initialization value followed by ENTER. When not using the Aux Enable function, this is the value that the auxiliary setpoint initializes to upon power- up or exiting the program mode. (Must be less than or equal to the Max Aux Setpoint Setting) AUX DROOP (%) dflt= 0.0 (0.0, 100) Enter the droop percentage followed by the ENTER key. If required, typically set between 4-6%. AUX PID PROPORTIONAL GAIN (%) dflt= 1.0 (0.0, 100) Enter the AUX PID proportional gain value followed by ENTER. This value is used to set auxiliary control response. This value can be changed in the Run Mode while the turbine is operating. If unknown, a recommended starting value is 1%. AUX PID INTEGRAL GAIN (%) dflt= 0.3 (0.001, 50) Enter the AUX PID integral gain value followed by ENTER. This value is used to set auxiliary control response. This value can be changed in the Run Mode while the turbine is operating. If unknown, a recommended starting value is 3%. AUX PID DERIVATIVE RATIO (%) dflt= 100 (0.01, 100) Enter the AUX PID derivative ratio followed by ENTER. This value is used to set auxiliary control response. This value can be changed in the Service Mode while the turbine is operating. If unknown, a recommended starting value is 100%. TIEBRKR OPEN AUX DSBL ? dflt= YES (Yes/No) Select YES followed by ENTER if the auxiliary control will be disabled when the utility tie breaker opens. If NO is selected, then auxiliary control will not be disabled when the utility tie breaker is opened. GENBRKR OPEN AUX DSBL ? dflt= YES (Yes/No) Select YES followed by ENTER if the auxiliary control will be disabled when the generator breaker opens. If NO is selected, then auxiliary control will not be disabled when the generator breaker is opened. USE REMOTE AUX SETTING ? dflt= NO (Yes/No) Set to YES to allow the aux setpoint to be adjusted from an analog input. (Must program a remote auxiliary setpoint analog input) 96 Woodward
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REMOTE AUX MAX RATE (UNITS/sec) dflt= 5.0 (0.1, 1000) Enter the maximum rate at which the remote input will move the aux setpoint followed by the ENTER key. AUXILIARY UNITS OF MEASURE: (must choose from list) Scroll through the option list by using the Adjust Up/Down Arrows or by selecting the NO key until the option desired appears, then press the YES or ENTER keys to select the option/function. Options: psi t/h kPa k#/hr MW #/hr KW kg/cm2 degF bar degC atm (none)
Manual 85017V1
SPEED SETPOINT UPPER LIMIT (rpm) dflt= 3780 (0.0, 20000) Set the maximum speed setpoint that cascade controller can raise the speed setpoint to followed by the ENTER key. (Must be less than or equal to the Maximum Governor Speed Setpt Setting) MAX SPEED SETPOINT RATE (rpm/sec) dflt= 20 (0.1, 100) Set the maximum rate at which the cascade control can vary the speed setpoint followed by the ENTER key. CASCADE DROOP (%) dflt= 0.0 (0.0, 100) Enter the droop percentage followed by the ENTER key. If needed, typically set between 4-6%. CASCADE PID PROPORTIONAL GAIN (%) dflt= 5.0 (0.0, 100) Enter the cascade PID proportional gain value followed by ENTER. This value is used to set cascade control response. This value can be changed in the Run Mode while the turbine is operating. If unknown, a recommended starting value is 5%. CASCADE PID INTEGRAL GAIN (%) dflt= 0.3 (0.001, 50.0) Enter the cascade PID integral gain value followed by ENTER. This value is used to set cascade control response. This value can be changed in the Run Mode while the turbine is operating. If unknown, a recommended starting value is 0.3%. CASCADE PID DERIVATIVE RATIO (%) dflt= 100 (0.01, 100) Enter the cascade PID derivative ratio followed by ENTER. This value is used to set cascade control response. This value can be changed in the Service Mode while the turbine is operating. If unknown, a recommended starting value is 100%. USE REMOTE CASCADE SETTING? dflt= NO (Yes/No) Set to YES to allow the Cascade setpoint to be adjusted from an analog input. (Must program a remote cascade setpoint analog input RMT CASCADE MAX RATE (UNITS/sec) dflt= 5.0 (0.1, 1000) Enter the maximum rate at which the remote input will move the cascade setpoint followed by the ENTER key. CASCADE UNITS OF MEASURE: (must choose from list) Scroll through the option list by using the Adjust Up/Down Arrows or by selecting the NO key until the option desired appears, then press the YES or ENTER keys to select the option/function. Options: psi kPa MW KW degF degC t/h k#/hr kg/cm bar atm #/hr (none)
Readouts
When this header appears in the display, press the down arrow key to configure this block or press a left or right arrow key to select another block to configure. All six 420 mA analog readouts may be configured. The function that the readout uses must be programmed or an error message will occur. For example, to use the Cascade Setpoint readout, the Use Cascade function must be programmed.
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ANALOG READOUT # 1 FUNCTION (must choose from list) Scroll through the option list by using the Adjust Up/Down Arrows or by selecting the NO key until the option desired appears, then press the YES or ENTER keys to select the option/function. ANALOG READOUT OPTIONS Actual Speed Auxiliary Input Speed Setpoint Auxiliary Setpoint Remote Speed Setpt Rmt Auxiliary Setpt Load Share Input Valve Limiter Setpoint Sync Input Actuator Demand Readout KW Input Actuator 1 Readout Cascade Input Actuator 2 Readout Cascade Setpoint First Stg Press Input Rmt Cascade Setpt (Not Used) READOUT 14 mA VALUE (UNITS) dflt= 0.0 (-20000, 20000) Set the value (in engineering units) that corresponds to 4 milliamps (mA) on the analog output followed by the ENTER key. If the value on the display is correct, just select the ENTER key which will advance you to the next question. READOUT 120 mA VALUE (UNITS) dflt= 100 (-20000, 20000) Set the value (in engineering units) that corresponds to 20 milliamps (mA) on the analog output followed by the ENTER key. If the value on the display is correct, just select the ENTER key which will advance you to the next question. (Must be greater than the Readout 4 mA Value Setting) Readouts # 2 through # 6 are entered following the same rules as described for Readout # 1.
Relays Block
When this header appears in the display, press the down arrow key to configure this block or press a left or right arrow key to select another block to configure. You may configure up to six relays in addition to the two pre-assigned relays (Alarm, Shutdown). The relay can be configured as either a level switch or as an indication. An example of a level switch is a Speed Switch and an example of an indication is Cascade Control Enabled. USE RELAY # 1? dflt= NO (Yes/No) Press Set to YES followed by ENTER to use this relay output. Press NO followed by ENTER to skip to the next USE RELAY question. IS RELAY # 1 A LEVEL SWITCH? dflt= NO (Yes/No) Press YES followed by ENTER to use this relay output as a level switch. Press NO followed by ENTER to skip to the RELAY ENERGIZES ON: question.. RELAY 1 IS LEVEL SWITCH FOR : (must choose from list) Scroll through the option list by using the Adjust Up/Down Arrows or by selecting the NO key until the option desired appears, then press the YES or ENTER keys to select the option/function. LIST OF OPTIONS FOR LEVEL SWITCH Actual Speed Level Aux Setpoint Level Speed Setpoint Level Valve Limiter Level KW Input Level Actuator Demand (hand valve) Sync/Load Share Level Act 1 Output Level Cascade Input Level Act 2 Output Level Cascade Setpoint Level First Stg Press Level Aux Input Level Switch Woodward 99
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RELAY 1 ON LEVEL (UNITS) dflt= 0.0 (-20000, 20000) Enter the level switch ON setting in engineering units followed by the ENTER key. There is an ON and an OFF setting for each level switch option. This allows the user to program the desired hysteresis for the function selected. RELAY 1 OFF LEVEL (UNITS) dflt= 0.0 (-20000, 20000) Enter the level switch OFF setting in engineering units followed by the ENTER key. (Must be less than the Relay On Level Setting) RELAY 1 ENERGIZES ON : (must choose from list) Scroll through the option list by using the Adjust Up/Down Arrows or by selecting the NO key until the option desired appears, then press the YES or ENTER keys to select the option/function. OPTIONS FOR RELAYS IF USED TO INDICATE STATE Shutdown Condition Sync Enabled Trip Relay (addl trip relay output) Sync/Load Share Active Alarm Condition Load Share Control 505 Control OK Casc Control Enabled Overspeed Trip Cascade Control Active Overspeed Test Enabled Remote Casc Setpt Enabled Speed PID in Control Remote Casc Setpt Active Remote Speed Setpt Enabled Aux Control Enabled Remote Speed Setpt Active Aux Control Active Underspeed Switch Auxiliary PID in Control Auto Start Sequence Halted Remote Aux Setpt Enabled On-Line PID Dynamics Mode Remote Aux Setpt Active Local Control Mode Valve Limiter in Control Frequency Control Armed F3 Key Selected Frequency Control F4 Key Selected Modbus Command Selected Relay outputs # 2 through # 6 are entered following the same rules as described for Relay output # 1.
Communications Block
When this header appears in the display, press the down arrow key to configure this block or press a left or right arrow key to select another block to configure. USE COMMUNICATIONS? dflt= NO (Yes/No) Set to YES followed by ENTER to use the Modbus communications feature of the 505. There are two identical Modbus ports available. Either or both can be configured for use. Select NO followed by ENTER if Modbus communications will not be used. USE MODBUS PORT 1? dflt= NO (Yes/No) Set to YES followed by ENTER to use the Modbus Port 1. Set to NO followed by ENTER to skip to Use Modbus Port 2. If the displayed value is already correct, simply select ENTER. MODE: ASCII OR RTU dflt= 2 (1, 2) Enter the integer corresponding to the Modbus transmission mode required followed by the ENTER key. Enter a 1 for ASCII mode or a 2 for RTU mode. For more information on the difference between these modes, refer to Chapter 6. If the displayed value is already correct, simply select ENTER. MODBUS DEVICE NUMBER dflt= 1 (1, 247) Enter the integer corresponding to the Modbus device number/address required followed by the ENTER key. If the displayed value is already correct, simply select ENTER. 100 Woodward
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COMMUNICATIONS MODE dflt= 1 (1, 3) Enter the integer corresponding to the serial communications mode required followed by the ENTER key. Enter a 1 for RS-232, a 2 for RS-422 or a 3 for RS-485 communications. If the displayed value is already correct, simply select ENTER. PORT1 BAUD RATE dflt= 9 (1, 11) Enter the integer corresponding to the communications baud rate followed by the ENTER key. If the displayed value is already correct, simply select ENTER. 1 = 110 2 = 300 3 = 600 4 = 1200 5 = 1800 6 = 2400 7 = 4800 8 = 9600 9 = 19200 10 = 38400 11 = 57600 PORT 1 STOP BITS dflt= 1 (1, 3) Enter the integer corresponding to the stop bits required followed by the ENTER key. If the displayed value is already correct, simply select ENTER. Enter a 1 for 1 stop bit, a 2 for 1.5 stop bits or a 3 for 2 stop bits. PORT 1 PARITY dflt= 1 (1, 3) Enter the integer corresponding to the parity required followed by the ENTER key. If the displayed value is already correct, simply select ENTER. Enter a 1 for none, a 2 for odd parity or a 3 for even parity. USE MODBUS PORT 2? dflt= NO (Yes/No) Set to YES followed by ENTER to use the Modbus Port 2. If the displayed value is already correct, simply select ENTER. Modbus Port # 2 is entered following the same rules as described for Modbus Port # 1.
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Once the programming steps have been completed, the Program Mode can be exited (refer to Figure 4-4 Exiting the Program Mode). To exit the Program mode the CLEAR key is pressed twice. This initiates the 505 to save the configuration and to begin a Configuration Check procedure. If there are no errors in the programming, the 505 front-panel will return to the ready state and display the Controlling Parameter/Press Run or Program screen. However, if there is an error in the program, the Config ERRORPress PRGM display will appear along will the programming error(s) discovered. The next section identifies the various configuration error messages and explains the meaning of the error.
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Contact #xx Program ErrThe specified contact input was programmed for a function that is not also programmed to be used. Either the contact input was mis-programmed or the function required is mis-programmed. For example, contact input #1 is programmed for Remote Cascade Setpoint Enable but Remote Cascade Setpoint was not programmed under the Cascade Program Block.
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F3 Key Program ErrorThe F3 key was programmed for a function that is not also programmed to be used. Either F3 was mis-programmed or the function required was mis-programmed. For example, the F3 key is programmed for Remote Cascade Setpoint Enabled but Remote Cascade Setpoint was not programmed under the Cascade Program Block. F4 Key Program ErrorThe F4 key was programmed for a function that is not also programmed to be used. Either F4 was mis-programmed or the function required was mis-programmed. For example, the F4 key is programmed for Remote Cascade Setpoint Enabled but Remote Cascade Setpoint was not programmed under the Cascade Program Block.
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505 Digital Governor Driver Limits Overcurrent Undercurrent Max Output Current Range Max Output Impedance Min Stop Adjust Range Max Stop Adjust Range 20160 mA Range 217 mA 5 mA 10-200 mA 45 10-80 mA 100-200 mA
To ensure proper control to actuator resolution do not calibrate the span of the actuator output to less than a range of 100 mA (20160 mA output) or 12 mA (420 mA output). If necessary, the actuator to valve linkage may need to be adjusted to ensure proper 505 to valve resolution. Figures 4-5 and 4-6 graphically show the steps available to stroke the actuator output(s). The stroking option is only available when the 505 control is in a shutdown state. Also, the screens displayed varies with the number of actuators programmed. After enabling the stroke mode, there are options available to adjust the minimum and maximum stops and to manually stroke the output(s). The manual adjustment mode can be used to stroke the actuator and valves from 0 to 100% after the minimum and maximum positions have been adjusted. This allows both the actuator and valve to be tested for binding, play, resolution, linearity, and repeatability. The actuator and valve positions can be varied by using the ADJ UP and DOWN keys or keying in the position desired and pressing the ENTER key. When the ENTER key is pressed, the actuator output will step to the entered position. Press any available Run Mode key to exit the STROKE ACTUATORS mode. For example, pressing the SPEED key will disable the stroking function and display the speed information. To return to the STROKE ACTUATORS mode, the ACT key must be selected again and the keystrokes to enter this mode must be repeated. As a safety precaution, if the turbine speed ever exceeds 1000 rpm, the STROKE ACTUATORS mode is disabled. As a safety precaution, if turbine speed ever exceeds 1000 rpm, the STROKE ACTUATORS mode will be automatically disabled, and actuator currents taken to zero.
Calibration/Stroking Procedure
(for single actuator output configuration)
WARNING
Before calibrating or testing, the unit must be tripped and the steam supply removed. This is to ensure that opening the control valve(s) will not allow steam into the turbine. Overspeed sensing and its relay are disabled during this process. Overspeeding the turbine may cause damage to turbine and can cause severe injury or death to personnel. STEAM TO THE TURBINE MUST BE SHUT OFF BY OTHER MEANS DURING THIS PROCESS.
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1. The 505s Emergency shutdown contact input must be closed or jumpered throughout this procedure (or the 505s actuator current output will go to ZERO current). 2. Execute a system RESET command (Press the 505 Reset key). 3. Press the 505s front panel Emergency Shutdown button. 4. Press the ACT key then the SCROLL DOWN key until the Stroke ActuatorsDsbled, Steam Must be Off message appears. (Verify that the turbines steam supply has been shutoff before by an external Trip and Throttle valve.) 5. Press the YES key (This will cause the screen to display a Stroke to Min Enabled, Min Curr Adjust * 20.000 message). 6. Press the YES key to enable this mode or the Scroll Down Arrow to step to the mode desired. (Refer to Figure 4-5). 6a. Stroke to MinEnabld, Min Curr Adjust * XXX.XXPress YES to force the actuator output to the minimum stop. The message will display At Min and the actuator output current will move to its minimum setting. The minimum current value can be adjusted only when the at sign (@) is on the bottom line of the display. Press the SELECT key to move the @ symbol between the top and bottom lines. Press the ADJ UP or DOWN keys to change the 0% actuator current level. Press the SCROLL DOWN ARROW to step the next desired mode, or the CLEAR key twice to save changes, and exit Calibration mode. 6b. Stroke to MaxEnabld, Max Curr Adjust * XXX.XXPress YES to force the actuator output to the maximum stop. The message will display At Max and the actuator output current will move to its maximum setting. The maximum current value can be adjusted only when the at sign (@) is on the bottom line of the display. Press the SELECT key to move the @ symbol between the top and bottom lines. Press the ADJ UP or DOWN keys to change the 100% actuator current DOWN ARROW to step the next desired mode, or the CLEAR key twice to save changes and exit Calibration mode. 6c. Manually AdjustEnabld, Stroke Valve XXX.XXPress the ADJ UP, ADJ DOWN keys from this screen to move the valves output current between 0-100% at a 5%/second rate. This allows both the actuator and valve to be tested for binding, play, resolution, linearity, and repeatability. Press the YES key at any time to allow a setting to be directly Entered. The message will display Manual when the ENTER mode is allowed. When in the Manual mode, press the ENTER key, enter the setting desired, then press the ENTER key again. This will step the actuator output to a specific position instantly. Press the ADJ UP/DOWN or No keys at any time to switch back to the Enabld mode. When calibration is complete, 0 to 100% valve position as displayed by the 505 must equal 0 to 100% actual valve travel. Press the SCROLL DOWN ARROW to step the next desired mode, or the CLEAR key twice to save changes and exit Calibration mode. 7. Press the CLEAR key twice to permanently save any minimum or maximum actuator settings into the 505. If variables are tuned or changed but not stored in EEPROM by pressing the CLEAR key twice, then those changes will be lost if power is removed from the control or if the control receives a CPU reset.
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Calibration/Stroking Procedure
(for dual actuator output configuration)
WARNING
Before calibrating or testing, the unit must be tripped and the steam supply removed. This is to ensure that opening the control valve(s) will not allow steam into the turbine. Overspeed sensing and its relay are disabled during this process. Overspeeding the turbine may cause damage to turbine and can cause severe injury or death to personnel. STEAM TO THE TURBINE MUST BE SHUT OFF BY OTHER MEANS DURING THIS PROCESS. 1. The 505s Emergency shutdown contact input must be closed or jumpered throughout this procedure (or the 505s actuator current output will go to ZERO current. 2. Execute a system RESET command (Press the 505 Reset key). 3. Press the 505s front panel Emergency Shutdown button. 4. Press the ACT key then the SCROLL DOWN key until the Stroke ActuatorsDsbld, Steam Must be Off message appears. (Verify that the turbines steam supply has been shutoff before by an external Trip and Throttle valve.) 5. Press the YES key (This will cause the screen to display a Act #1 to Min Enabld, Min Curr Adjust * 20.000 message). 6. Press the YES key to enable this mode or the Scroll Down Arrow to step to the mode desired. (Refer to Figure 4-6). 6a. Act #1 to MinEnabld, Min Curr Adjust * XXX.XXPress YES to force the actuator output to the minimum stop. The message will display At Min and the actuator output current will move to its minimum setting. The minimum current value can be adjusted only when the at sign (@) is on the bottom line of the display. Press the SELECT key to move the @ symbol between the top and bottom lines. Press the ADJ UP or DOWN keys to change the 0% actuator current level. Press the SCROLL DOWN ARROW to step the next desired mode, or the CLEAR key twice to save changes, and exit Calibration mode. 6b. Act #1 to MaxEnabld, Max Curr Adjust * XXX.XXPress YES to force the actuator output to the maximum stop. The message will display At Max and the actuator output current will move to its maximum setting. The maximum current value can be adjusted only when the at sign (@) is on the bottom line of the display. Press the SELECT key to move the @ symbol between the top and bottom lines. Press the ADJ UP or DOWN keys to change the 100% actuator current DOWN ARROW to step the next desired mode, or the CLEAR key twice to save changes and exit Calibration mode. 6c. Manually AdjustEnabld, Stroke Valve XXX.XXPress the ADJ UP, ADJ DOWN keys from this screen to move the valves output current between 0-100% at a 5%/second rate. This allows both the actuator and valve to be tested for binding, play, resolution, linearity, and repeatability. Press the YES key at any time to allow a setting to be directly Entered. The message will display Manual when the ENTER mode is allowed. When in the Manual mode, press the ENTER key, enter the setting desired, then press the ENTER key again. This will step the actuator output to a specific position instantly. Press the ADJ UP/DOWN or No keys at any time to switch back to the Enabld mode.
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505 Digital Governor When calibration is complete, 0 to 100% valve position as displayed by the 505 must equal 0 to 100% actual valve travel. Press the SCROLL DOWN ARROW to step the next desired mode, or the CLEAR key twice to save changes and exit Calibration mode.
7.
Similarly, for Act #2: 7a. Act #2 to MinEnabld, Min Curr Adjust * XXX.XX Press YES to force the actuator output to the minimum stop. The message will display At Min and the actuator output current will move to its minimum setting. The minimum current value can be adjusted only when the at sign (@) is on the bottom line of the display. Press the SELECT key to move the @ symbol between the top and bottom lines. Press the ADJ UP or DOWN keys to change the 0% actuator current level. Press the SCROLL DOWN ARROW to step the next desired mode, or the CLEAR key twice to save changes, and exit Calibration mode. 7b. Act #2 to MaxEnabld, Max Curr Adjust * XXX.XX Press YES to force the actuator output to the maximum stop. The message will display At Max and the actuator output current will move to its maximum setting. The maximum current value can be adjusted only when the at sign (@) is on the bottom line of the display. Press the SELECT key to move the @ symbol between the top and bottom lines. Press the ADJ UP or DOWN keys to change the 100% actuator current DOWN ARROW to step the next desired mode, or the CLEAR key twice to save changes and exit Calibration mode. 7c. Manually AdjustEnabld, Stroke Valve XXX.XX Press the ADJ UP, ADJ DOWN keys from this screen to move the valves output current between 0-100% at a 5%/second rate. This allows both the actuator and valve to be tested for binding, play, resolution, linearity, and repeatability. Press the YES key at any time to allow a setting to be directly Entered. The message will display Manual when the ENTER mode is allowed. When in the Manual mode, press the ENTER key, enter the setting desired, then press the ENTER key again. This will step the actuator output to a specific position instantly. Press the ADJ UP/DOWN or No keys at any time to switch back to the Enabld mode. When calibration is complete, 0 to 100% valve position as displayed by the 505 must equal 0 to 100% actual valve travel. Press the SCROLL DOWN ARROW to step the next desired mode, or the CLEAR key twice to save changes and exit Calibration mode.
8. Press the CLEAR key twice to permanently save any minimum or maximum actuator settings into the 505. If variables are tuned or changed but not stored in EEPROM by pressing the CLEAR key twice, then those changes will be lost if power is removed from the control or if the control receives a CPU reset. If changes are made to the minimum or maximum current values, they can be recorded on the Program Mode worksheets under the Driver Configurations block.
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Pressing any available Run Mode key will exit the STROKE ACTUATORS/VALVE mode. Exiting the STROKE ACTUATORS/VALVE mode by a RUN MODE key will not permanently save any calibration changes.
CAUTION
Press the CLEAR key twice to permanently save any minimum or maximum actuator settings into the 505. If variables are tuned or changed but not stored in EEPROM by pressing the CLEAR key twice, then those changes will be lost if power is removed from the control or if the control receives a CPU reset.
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505 Digital Governor Stroke Actuator Messages Meaning Stroke actuators function is disabled Stroke actuators function is enabled Actuator output is set to the minimum value ( 0% ) Actuator output is set to the maximum value ( 100% ) Actuator output is in manual mode
CAUTION
Press the CLEAR key twice to permanently save any minimum or maximum actuator settings into the 505. If variables are tuned or changed but not stored in EEPROM by pressing the CLEAR key twice, then those changes will be lost if power is removed from the control or if the control receives a CPU reset.
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An overview of Run mode keys and screens is shown in Figure 5-2. This diagram shows all of the potential screens that could appear. However, only the screens that are related to the 505s programmed functionality will appear. Figure 5-2 also shows the keys that are active for each screen. The hot keys (Speed, Aux, etc.) are always active if the function is programmed. The ADJUST UP/DOWN, ENTER, YES/NO keys, however, are only active with certain screens. Figure 5-2 can be referred to, when determining what keys are active and what screens will appear on the display.
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Manual 85017V1
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Trip Messages Message 8 External Trip Input Enter Shutdown Button Overspeed All Speed Probes Failed Actuator #1 Fault Actuator #2 Fault Aux Input Failed External Trip 2 External Trip 3 External Trip 4 External Trip 5 Comm Link #1 Trip Comm Link #2 Trip KW Input Failed Tie Breaker Opened Generator Breaker Open Power Up Trip Shutdown Complete Idle/Rated Messages Message 1 Stopped Speed/Off-Line Mvg to Idle At Idle Spd In Crit Band Mvg to Rated At Rated Spd Rtd Inhibited Idle Inhibited Auto Start Messages Message 2 Disabled Halted Mvg Low Idle At Low Idle Mvg Hi Idle In Crit Band At High Idle Mvg to Rated Completed Control Messages Message 3 Disabled Inhibited Enabled In Control Remote Control Controlling Parameter Messages Message 7 Shutdown Controlled Shutdown Max Actuator Valve Limiter Remote Auxiliary Auxiliary Control Configuration Error Start Perm Not Met Ready to Start Manual Start Auto Start Semi Auto Start Idle/Rated Start Auto Start Sequence Frequency/Speed Synchronizing Load Share/Speed Remote Cascade/Speed Cascade/Speed Remote/Speed Speed/On-Line Speed/Off-Line Aux Messages (if using aux enable) Message 5 Disabled Inhibited Enabled Active/Not in Ctrl Active w/Rmt Setpt In Control Remote Control Aux Messages (if using aux as a limiter) Message 5 Inhibited Enabled Enabled w/Rmt Setpt Active w/Rmt Setpt Active/Not Lmting Control w/Rmt Setpt In Control
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The ADJUST UP/DOWN keys are active when a setpoint is displayed and the setpoint is not in a remote control or tracking mode. The ENTER key is active whenever the ADJUST UP/DOWN keys are active. This is when the setpoint is shown on the display and the setpoint is not in remote control or tracking mode. The YES/NO keys are active whenever a status indication is shown on the display and an enable/disable function is valid. The CAS, AUX, KW, and RMT keys are only active if the function is configured in the Program Mode. The SPEED, ACTR, LMTR, CONT, and DYN keys are always active. The PRGM, RUN, STOP, RESET, and ALARM keys are always active. The F3 and F4 function keys are only active if they are configured. The OVERSPEED TEST ENBL is conditionally active (only active when OSPD test is permissible).
Starting Procedures
Refer to the turbine manufacturers operating procedures for complete information on turbine start up, and Chapter 3 of this manual for a step by step procedure, depending on the start mode selected. The following is a typical startup procedure:
WARNING
The engine, turbine, or other type of prime mover should be equipped with an overspeed shutdown device to protect against runaway or damage to the prime mover with possible personal injury, loss of life, or property damage. The overspeed shutdown device must be totally independent of the prime mover control system. An overtemperature or overpressure shutdown device may also be needed for safety, as appropriate. 1. Press the RESET key to clear all alarms and trips. If the 505s RESET CLEARS TRIP setting is programmed "YES", the 505's shutdown relay will reset or energize upon pressing the RESET key after a shutdown. If the RESET CLEARS TRIP OUTPUT setting is programmed "NO", the 505's shutdown relay will reset or energize upon pressing the Reset key ONLY after all trip conditions are cleared. 2. Press the RUN key to initiate the selected start-up mode. The front panel display will automatically jump to the SPEED screen (if auto or manual start is programmed) or to the LMTR screen (if semi-auto start is programmed). If a semi-automatic start mode is configured, the valve limiter must be manually increased to open the control valve. A Start Perm Not Closed alarm will be issued if the application is using a Start Permissive contact input and this contact input was not closed when the RUN command was issued. 3. After the selected start-up mode has been performed, the turbine will operate at the minimum or idle speed setting. The 505s speed setpoint will move to minimum governor speed unless an idle speed is programmed. The Idle/Rated or Auto Start Sequence functions must be programmed for the turbine to control at idle speed. An operator at this time may vary turbine speed through the 505's keypad, external switches or communication links. The Run and Reset commands can be selected from the 505s service panel, contact input closures (if programmed), or from a Modbus communications link. In addition, the following indications are available through the Modbus links: Speed Setpt Moving to Min, Start Permissive closed, and Start Permissive Not Closed Alarm indication. Woodward 117
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Idle/Rated Start
For details on the idle/rated startup, refer to Chapter 3. When a RUN command is issued, the 505 automatically displays the SPEED screen and shows the Idle/Rated status. The speed setpoint is instantly set to the actual turbines speed. To increase the speed to the programmed Rated Setpt setting, select the Rated command. A Rated command can be issued by pressing the front panel YES key from the Idle/Rtd screen (screen 1), closing the Idle/Rated contact (if programmed) or selecting a Go To Rated command from Modbus communications.
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When the speed setpoint is ramping to the Rated Setpoint setting it can be stopped at any point that is not within a critical speed avoidance band by issuing a Speed Setpt Raise or Lower command. This can be done by pressing the ADJUST UP or DOWN from the front panel SPEED screen (screens 1,2,3 or 4), closing a Speed Raise/Lower contact input or selecting Speed Raise or Lower from a Modbus communications link. The Speed setpoint will again ramp to the Rated Speed setting if the Rated command is re-issued. To re-issue the Rated command press the front panel YES key from the Idl/Rtd screen (screen 1), toggle the Idle/Rated contact open and closed again (if programmed) or select Go To Rated from a Modbus communications link. The Speed setpoint will ramp to the Idle Speed setting upon startup. However, the Idle Speed setting can be re-selected, when conditions allow, (see Chapter 3) by pressing the front panel NO key from the Idl/Rtd screen (screen 1), opening the Idle/Rated contact (if programmed), or selecting Go To Idle from a Modbus communications link. Another feature of Idle/Rated function is the Ramp to Rated option which allows the Speed setpoint to only move to the Rated Speed setting; Idle is not selectable. This feature is configurable in the Service Mode only. When this feature is used with the Idle/Rated contact input, closing the contact results in the Speed setpoint ramping to the Rated Speed setting and opening the contact stops the speed setpoint ramprather than selecting Idle. To continue ramping to the Rated Speed setting, re-close the contact, press the front panel YES key from the Idl/Rtd screen (screen 1) or select Go To Rated from Modbus communications. Table 5-2 lists the Idle/Rated status messages that may appear on the front panel display and the meanings of each. Message 1 Stopped Mvg to Idle At Idle Spd In Crit Band Mvg to Rated At Rated Spd Rtd Inhibited Idle Inhibited Meaning Idle/Rated ramp has been stopped Speed Setpt is moving to idle Speed Setpt is at the idle Setpt Speed Setpt is moving through the critical avoidance band Speed Setpt is moving to the rated Setpt Speed Setpt is at the rated Setpt Selection of rated is not allowed Selection of idle is not allowed Table 5-2. Idle/Rated Messages
The following indications are available through the Modbus links: Ramping to Idle, At Idle, Turbine in Critical Speed Band, Ramping to Rated, and At Rated. In addition to these indications, the Idle Speed Setpoint and Rated Speed Setpoint analog values are also available.
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The following Auto Start Sequence indications are available through the Modbus links: Setpt Moving to Min, Setpt at Low Idle, Ramping to High Idle, Setpt at High Idle, Turbine in Critical Speed Band, Ramping to Rated, and At Rated. In addition to these indications, the Low Idle Speed Setpoint, Low Idle Delay Time, Time Remaining at Low Idle, Low Idle to High Idle Rate, High Idle Speed Setpoint, High Idle Delay Time, Time Remaining at High Idle, High Idle to Rated Rate, Rated Speed Setpoint, Run Time (hours), and Hours Since Trip analog values are also available providing comprehensive sequence information.
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The Speed setpoint can also be directly entered from either of the Modbus links, however, the allowed range is between the minimum and maximum governor speed settings. The allowed setpoint range is limited between the minimum load and the maximum governor settings if the unit is driving a generator and the unit is on-line. Both the speed setpoint and the Modbus Entered Speed setpoint are available over the communication link to provide feedback for directly entered Modbus values.
Speed Control
Once the turbine is in speed control at minimum governor speed or rated speed, the speed setpoint can be adjusted with the ADJUST UP or DOWN front panel keys from the Speed screen (screen 4), Speed Setpoint Raise or Lower contact inputs, or commands through a Modbus link. In addition the setpoint can be directly entered using the ENTER key from a Setpoint display or through the communication links (see Direct Setpoint Entry above). The following speed control indications are available through the Modbus links: Speed PID in Control and Speed at or above Min Gov. In addition to these indications the Speed Setpoint, Actual Turbine Speed, Speed Sensor #1 Input, Speed Sensor #2 Input, and Speed Control PID Output analog values are also available.
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If an external devices trip setting is being tested the Speed Setpoint can be raised up to the 505s OVERSPEED TEST LIMIT setting, by not releasing the OSPD key and continuing to adjust the 505s Speed Setpoint. The Overspeed Test LED will blink at a faster rate when the OVERSPEED TEST LIMIT is reached, indicating the maximum speed setpoint is reached and the unit should have tripped on the external trip device.
Alternatively the turbines overspeed logic and circuitry can be tested remotely, by programming an Overspeed Test contact input. The Overspeed Test contact functions as the OSPD key on the 505s service panel. When the conditions outlined in the above procedure are met, closing this contact allows the Speed setpoint to be increased up to the Overspeed Test limit setting. The testing procedure is similar to using the OSPD key. An Overspeed Test Enabled relay can be programmed to provide the same status feedback as the front panel Overspeed Test LED. The Overspeed Test function cannot be performed over the Modbus communications, however, the Overspeed Test Permissive, Overspeed Test In Progress, Overspeed Alarm, and Overspeed Trip indications are available through Modbus.
F3 and F4 Keys
The F-key (F3 & F4) screens appear only when programmed for a specific function. The screens that appear will vary depending on the function programmed. The F-keys can be programmed to perform a variety of functions including: Local/Remote Casc Control Enable Idle/Rated Remote Casc Setpt Enable Halt/Continue Auto Start Sequence Aux Control Enable Remote Speed Setpt Enable Remote Aux Setpt Enable Sync Enable Energize Relay Output Freq Arm/Disarm In the RUN mode, the assigned function may be selected or deselected by pressing the assigned function key, then the Yes or No keys respectively. The screen will display the present status of the function and prompt the appropriate (Yes/No) key required to change the status.
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The valve limiter can be adjusted with the ADJUST UP or DOWN front panel keys from any Limiter screen, Valve Limiter Raise or Lower contact inputs (if programmed), or commands through a Modbus link. In addition the setpoint can be directly entered using the ENTER key from any Limiter screen. The following valve limiter indications are available through the Modbus links: Valve Limiter at Min, Valve Limiter at Max, and Valve Limiter In Control of actuator output. In addition to these indications the Valve Limiter Setpoint, Actuator LSS, Actuator #1 Output and Actuator #2 Output analog values are also available.
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Table 5-4 shows a complete listing of all possible controlling parameters and their meanings.
Message 7 Shutdown Controlled Shutdown Start Perm Not Met Max Actuator Valve Limiter Ready to Start Manual Start Auto Start Semi Auto Start Idle/Rated Start Auto Start Sequence Remote/Speed Speed/On-Line Speed/Off-Line Frequency/Speed Synchronizing Load Share/Speed Auxiliary Control Remote Auxiliary Cascade/Speed Rmt Cascade/Speed Configuration Error Meaning Control is tripped A controlled shutdown is being executed The start permissive contact input is not closed The actuator output is at its maximum position The Valve Limiter is in control of the actuator output The units start permissives are OK and the unit is ready to start The 505 is running and in the Manual start mode The 505 is running and in the Automatic start mode The 505 is running and in the Semi-automatic start mode The 505 is running and in the Idle/Rated sequence mode The 505 is running and in the Automatic Start Sequence mode Speed PID is in control, the Speed Setpoint is in remote control Speed PID is in control using On-Line dynamics Speed PID is in control using Off-Line dynamics Speed PID is in control with the gen. breaker closed and tie breaker open Speed PID is in control with the Synch. analog input biasing its setpoint Speed PID is in control with Sync/Ld Share analog input biasing its setpoint Aux PID is in control of the actuator output Aux PID is in control and the Aux Setpt is in remote control Casc & Speed PIDs are in control Casc & Speed PIDs are in control, and Casc Setpt is in remote control The 505 program has been configured incorrectly
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For a complete listing of Shutdown/Trip causes, refer to the Trips section later in this chapter. The Controlling Parameter and Highest Speed Reached values are also available through the Modbus links.
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Auxiliary control is disabled by pressing the front panel NO key from the Aux Status screen (screen 2), opening the Aux Control Enable/Disable contact (if programmed), or selecting Aux Disable from either Modbus communications link see Table 5-5). Auxiliary control is also disabled if Cascade control is enabled, or Remote Speed Setpoint control is enabled. Aux control is disabled and inhibited if a controlled shutdown is selected, the Auxiliary input fails or the unit shuts down. Auxiliary control can be enabled but not active if the generator and/or utility tie breaker disable features are programmed.
Message 5 Disabled Inhibited Enabled Active/Not In Ctrl Active w/Rmt Setpt In Control Remote Control Meaning Aux control is disabled Aux is inhibited and cannot be enabled Aux is enabled but not in control due to gen/tie breaker status Aux is active but the PID is not in control (valve limiter control) Aux is active but not in control and the Setpt is in remote control Aux is active and in control of the actuator output Aux is in control and the Setpt is in remote control
The following auxiliary control indications are available through the Modbus links: Aux is Enabled, Aux is Active, Aux is In Control, Aux is Inhibited, Aux Active/Not Limiting, Aux Active/Not In Control, and the Aux Input Failed Alarm. In addition to these indications the Aux Setpoint, Aux Input, and Aux PID Output analog values are also available.
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Relay indications can be programmed to indicate Aux Control Active, Aux Control Enabled, or Aux PID In Control status.
The following remote auxiliary control indications are available through the Modbus links: Remote Aux is Enabled, Remote Aux is Active, Remote Aux is In Control, Remote Aux is Inhibited, and Remote Aux Input Failed Alarm. In addition to these indications, the Remote Aux Input Setpoint is also available. Relay indications can be programmed to indicate Remote Aux Control Active and Remote Aux Control Enabled status.
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The following Remote control indications are available through the Modbus links: Remote Speed Setpt is Enabled, Remote Speed Setpt is Active, Remote Speed Setpt is In Control, Remote Speed Setpt is Inhibited, and the Remote Speed Setpt Input Failed Alarm. In addition to these indications, Remote Speed Setpt Input analog value is also available. Relay indications can be programmed to indicate Remote Speed Setpt Active and Remote Speed Setpt Enabled status.
The following synchronizing and loadsharing control indications are available through the Modbus links: Generator Breaker Status, Utility Tie Breaker Status, Frequency Control, Sync is Enabled, Sync or Loadshare is In Control, Sync or Loadshare is Inhibited, and the Sync/Loadshare Input Failed Alarm. In addition to these indications, Sync/Loadshare Input analog value is also available. Relay indications can be programmed to indicate Sync Enabled, Sync/Loadshare Enabled, Loadshare Control and Frequency Control status.
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The Cascade setpoint can be configured to either track the input for bumpless transfer into control or remain at the last setting. When using the tracking option, the cascade setpoint cannot be changed until Cascade control is enabled. The Cascade setpoint can be changed by pressing the ADJUST UP or DOWN keys from the Cascade setpoint screen (screen 1), closing a Cascade Setpt Raise/Lower contact input, or selecting Cascade Setpoint Raise or Lower commands from either Modbus communications link. In addition, the Cascade setpoint can be directly set to a value by pressing the front panel ENTER key from the Cascade Setpt screen or by Entering a new Cascade Setpt through either Modbus communications link. The Cascade Setpt Raise/Lower contact inputs have a dual function. If either contact is closed and the Cascade control is active, the cascade setpoint will be adjusted. If either contact is closed and the cascade control is not active, the Speed setpoint will be adjusted. The advantage of this feature is that only one set of raise/lower switches is required to adjust either setpoint. The Cascade setpoint can be directly set to a value by selecting the front panel ENTER key from the Cascade Setpt screen or by Entering a new Cascade Setpt through either Modbus communications link.
Message 5 Disabled Inhibited Enabled In Control Active/Not Spd Ctrl Active w/Rmt Setpt In Ctrl w/Rmt Setpt Meaning Cascade control is disabled Cascade is inhibited and cannot be enabled Cascade is enabled but not in control of actuator Cascade is in control of actuator output Cascade is active but Speed PID is not in control of actuator Cascade is active but Speed PID is not in control, Setpt is in remote control Cascade is in control, Speed PID is in control, Setpt is in remote control
The following Cascade control indications are available through the Modbus links: Cascade is Enabled, Cascade is Active, Cascade is In Control, Cascade is Inhibited, and the Cascade Input Failed Alarm. In addition to these indications the Cascade Setpoint, Cascade Input, and Cascade PID Output analog values are also available. Relay indications can be programmed to indicate Cascade Control Active, and Cascade Control Enabled.
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Message 4 Disabled Inhibited Enabled Active In Control
The remote cascade control indications shown in Table 5-11 are available through the Modbus links: Remote Cascade is Enabled, Remote Cascade is Active, Remote Cascade is In Control, Remote Cascade is Inhibited, and Remote Cascade Input Failed Alarm. In addition to these indications, the Remote Cascade Input Setpoint is also available. Relay indications can be programmed to indicate Remote Cascade Control Active and Remote Cascade Control Enabled status.
Alarms
The ALARM key is always active in the RUN mode. Figure 5-16 shows the screen that appears when this key is pressed. If there are no alarms detected, the screen will display the Alarms Cleared message. When an alarm is detected, the Alarm relay is energized and the front panel Alarm key illuminates. In addition, the screen will automatically jump to the ALARM screen (as defaulted in the Service mode) and display the alarm condition. Table 5-12 lists all the potential alarm conditions and their cause. If more than one alarm condition is present, pressing the Down Arrow key will scroll through all active alarms. To view the most recent alarm, select the ALARM key. To clear any alarms that are no longer present, press the front panel RESET key, close the Reset contact input, or select Reset from either Modbus communications link.
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Meaning Speed probe #1 failure( < Failed Speed Level or 1 Vrms) Speed probe #2 failure( < Failed Speed Level or 1 Vrms) Cascade analog input failure detected ( > 22 mA or < 2 mA) Auxiliary analog input failure detected ( > 22 mA or < 2 mA) KW analog input failure detected (> 22 mA or < 2 mA) FSP analog input failure detected (> 22 mA or < 2 mA) Remote Speed Setpt analog input failure ( > 22 mA or < 2 mA) Remote Casc Input Fld Remote Cascade Setpt analog input failure ( > 22 mA or < 2 mA) Remote Aux Input Fld Remote Aux Setpt analog input failure ( > 22 mA or < 2 mA) Load Share Input Fld Load Share analog input failure detected ( > 22 mA or < 2 mA) Act #1 Fault Actuator #1 fault detected (an open or short circuit was sensed) Act #2 Fault Actuator #2 fault detected (an open or short circuit was sensed) Start Perm Not Closed Run was selected while the Start Perm contact in was not closed Comm Link #1 Failed Modbus com link #1 was detected as failedtime out error Comm Link #2 Failed Modbus com link #2 was detected as failedtime out error Turbine Trip Turbine is tripped alarm indication Overspeed Turbine overspeed alarm Tie Breaker Opened Utility Tie breaker was opened after it was closed Gen Breaker Opened Generator breaker was opened after it was closed Tie Brkr Open/No Casc Utility Tie breaker was opened when Cascade was active Gen Brkr Open/No Casc Generator breaker was opened when Cascade was active Tie Brkr Open/No Remote Util. Tie breaker was opened when Remote Spd Setpt was active Gen Brkr Open/No Remote Generator breaker was opened when Remote Spd Setpt was active Tie Brkr Open/No Aux Utility Tie breaker was opened when Auxiliary was active Gen Brkr Open/No Aux Generator breaker was opened when Auxiliary was active Alarms Cleared All alarms are clearedno alarms are present
Each individual alarm condition is available through the Modbus links to monitor the control status. A common alarm indication is also provided. Relay indications can be programmed to indicate a 505 Common Alarm, in addition to the dedicated Alarm Relay output.
Trips
Figure 6-17 shows the screen that appears when there is a trip condition. The cause of the last trip can be seen under the CONT key (screen 2). Table 5-13 lists all the potential trip conditions and their cause.
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Message 6 External Trip Input External Trip 2 External Trip 3 External Trip 4 External Trip 5 Emer Shutdown Button Overspeed All Speed Probes Failed Actuator #1 Fault Actuator #2 Fault Aux Input Failed Comm Link #1 Trip Comm Link #2 Trip KW Input Failed Tie Breaker Opened Generator Breaker Open Power Up Trip Shutdown Complete
Each individual trip condition is available through the Modbus links to monitor the control status. A common trip indication is also provided. Relay indications can be programmed to indicate a 505 Shutdown Condition (energizes for a shutdown condition) or a Trip Relay (de-energizes for a shutdown/trip), in addition to the dedicated Emergency Trip Relay output.
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If the unit is not driving a generator and no Select On-Line Dynamics contact input is programmed, the Speed Off-Line dynamic settings are used when the turbine speed is below minimum governor speed; .On-Line dynamics are used if the turbine speed is above minimum governor speed. If the speed dynamics select contact is programmed, the turbine speed does not effect the dynamics selection. A relay can be programmed to indicate that the On-Line Dynamics mode is selected.
Cascade/Auxiliary Droop
The Cascade and Auxiliary controllers can be programmed to use droop for control loop stability. If the parameter being controlled (Cascade or Auxiliary) is also being controlled by another device (letdown station, boiler, or other turbine), droop is typically required for control loop stability. If required, no less than 5% droop is recommend for stable operation.
Tuning Derivative
The value of the Derivative Ratio (DR) term can range from 0.01 to 100. If unsure of the correct value, set the Speed controls DR term to 5% and the Aux & Cascade controllers DR terms to 100%. In order to simplify adjustment of the dynamics, adjusting the integral gain value sets both the I and D terms of the PID controller. The DR term establishes the degree of effect the integral gain value has on the "D" term, and changes the configuration of a controller from input rate sensitive (input dominant) to feedback rate sensitive (feedback dominant) and vice versa. Another possible use of the DR adjustment is to reconfigure the controller from a PID to a PI controller. This is done by adjusting the DR term to its upper or lower limits, depending on whether an input or feedback dominant controller is desired. A DR setting of 1 to 100 selects feedback dominant mode. A DR setting of .01 to 1 selects input dominant mode. A DR setting of .01 or 100 selects a PI only controller, input and feedback dominant respectively. The change from one of these configurations to the other may have no effect during normal operation, however, it can cause great differences in response when the governor is coming into control. (at startup, during a full load change, or during transfer of control from another channel). An input dominant controller is more sensitive to the change-of-rate of its input (Speed, Cascade in or Auxiliary in), and can therefore prevent overshoot of the setpoint better than a feedback dominant controller. Although this response is desirable during a startup or full load rejections, it can cause excessive control motions in some systems where a smooth transition response is desired. A controller configured as feedback dominant is more sensitive to the change-ofrate of its feedback (LSS). A feedback dominant controller has the ability to limit the rate of change of the LSS bus when a controller is near its setpoint but is not yet in control. This limiting of the LSS bus allows a feedback dominant controller to make smoother control transitions than an input dominant controller.
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Tuning Example
If the system is unstable, make sure the governor is the cause. This can be checked by closing the valve limiter until it has control of the actuator output. If the governor is causing the oscillation, time the oscillation cycle time. A rule-ofthumb is, if the systems oscillation cycle time is less than 1 second reduce the Proportional gain term. A rule-of-thumb is, if the systems oscillation cycle time is greater the 1 second reduce the Integral gain term (proportional gain may need to be increased also). On an initial startup with the 505, all PID dynamic gain terms will require adjustment to match the respective PIDs response to that of its control loop. There are multiple dynamic tuning methods available that can be used with the 505s PIDs to assist in determining the gain terms that provide optimum control loop response times (Ziegler Nichols, etc.). The following method is a simplified version of other tuning methods, and can be used to achieve PID gain values that are close to optimum: 1. Increase Derivative Ratio (DR) to 100 (This is the default setting). 2. Reduce integral gain to minimum. 3. Increase proportional gain until system just starts to oscillate. 4. Record the system gain (G) and oscillation period (T). 5. Set the dynamics as follows: For PID control set the proportional gain=0.60*G; integral gain=20/T; DR=5 For PI control set the proportional gain=0.45*G; integral gain=12/T; DR=100 This method of tuning will get the gain settings close, they can be fine-tuned from this point. Figure 5-18 shows the typical response to a load change when the dynamics are optimally adjusted.
NOTE
For additional information on PID settings, refer to Volume 2.
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Chapter 6. Communications
Modbus * Communications
The 505 control can communicate with plant distributed control systems and/or CRT based operator control panels through two Modbus * communication ports. These ports support RS-232, RS-422, RS-485 communications using ASCII or RTU MODBUS transmission protocols. Modbus utilizes a master/slave protocol. This protocol determines how a communication networks master and slave devices establish and break contact, how a sender is identified, how messages are exchanged, and how errors are detected.
*Modbus is a trademark of Modicon, Inc.
Monitor Only
The two Modbus communication ports, as defaulted from the factory, are not programmed. Although these ports are not programmed they continue to update all information to all registers. This allows the 505 to be monitored but not controlled from an external device. By simply connecting a monitoring device, configured to communicate through Modbus, and to the 505s defaulted protocol settings (parity, stop bits, etc.), this device can be used to monitor all the 505s controlling parameters, modes, etc. without effecting control. To use a 505 port to only monitor 505 parameters and operational modes or not use the port at all (Boolean and analog write commands are ignored), program the ports Use Modbus Port setting to NO.
Modbus Communication
The 505 control supports two Modbus transmission modes. A mode defines the individual units of information within a message and the numbering system used to transmit the data. Only one mode per Modbus network is allowed. The supported modes are ASCII (American Standard Code for Information Interchange), and RTU (Remote Terminal Unit). These modes are defined in the following table.
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Start Bits Data Bits per Char Parity Stop Bits Baud Rate
Error Checking
1 8 even, odd or none 1, 1.5, or 2 110,300, 600, 1200 1800, 2400, 4800, 9600 19200, 38400, or 57600 CRC(Cyclical Redundancy Check)
In the RTU mode, data is sent in 8-bit binary characters and transmitted in a continuous stream. In the ASCII mode, each binary character is divided into two 4-bit parts (high order and low order), changed to be represented by a hexadecimal equivalent, then transmitted, with breaks of up to 1 second possible. Because of these differences, data transmission with the ASCII mode is typically slower (see Figure 6-1 below).
The Modbus protocol allows one master and up to 247 slaves on a common network. Each slave is assigned a fixed, unique device address in the range of 1 to 247. With the Modbus protocol, only the network master can initiate a transaction. A transaction consists of a request from the master to a slave unit and the slaves response. The protocol and Modbus device number are set in the Program Mode and can be adjusted in the Service Mode, if required. The 505 control is programmed to function as a slave unit only. As a slave unit, the 505 will only respond to a transaction request by a master device. The 505 can directly communicate with a DCS or other Modbus supporting device on a single communications link, or through a multi-dropped network. If multi-dropping is used, up to 246 devices (505s or other customer devices) can be connected to one Master device on a single network. The control address is programmed under the 505s communications block and can be changed in the service mode, if needed. Each message to or from a master has a defined structure called the message frame. A frame consists of the slave device address, a code defining the requested data, and error checking information. See Figure 6-2.
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The Modbus function code tells the addressed slaves what function to perform. The following table lists the function codes supported by this control. Modbus Function Codes
Code 01 02 03 04 05 06 08 15 16 Definition Reference Address Read Digital Outputs 0XXXX (Raise/Lower and Enable/Disable Commands) Read Digital Inputs 1XXXX (Status Indications/Alarms and Trips) Read Analog Outputs 4XXXX Read Analog Inputs 3XXXX (Speed, Setpt, etc.) Write Single Discrete Output 0XXXX (Raise/Lower and Enable/Disable Commands) Write Single Register 4XXXX (Enter Setpt Directly) Loopback Diagnostic Test N/A (Subfunction 0 only) Write Digital Outputs 0XXXX Write Analog Outputs 4XXXX
When a Modbus message is received, it is checked for any errors or invalid data. If there is invalid data in the message, an error code is sent back to the master and the control issues an alarm message. The error codes are defined in the following table. The exception error status and respective error codes can be viewed in the Service mode under PORT # SETTINGS, where # is the number of the port (1 or 2). If the control has not received a message for the configured time-out period, the control will alarm with an error message, but no message is sent to the master. This time-out is defaulted to 2 seconds and only applies to units using both monitor and control (adjustable in the Service Mode).
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9 10 N/A
Port Adjustments
Before the 505 will communicate with the master device, the communication parameters must be verified. These values are set in the Program Mode and can be adjusted, if required, from the Service Mode. Modbus Communication Port Adjustments
Parameter Baud Rate Parity Stop Bits Driver Adjustment Range 110 TO 57600 NONE, ODD or EVEN 1 TO 2 RS232, RS422, or RS485
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Mode Of Transmission ASCII RTU Max Discretes 944 1188 Max Registers 59 118
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Addr 1:0001 1:0002 1:0003 1:0004 1:0005 1:0006 1:0007 1:0008 1:0009 1:0010 1:0011 1:0012 1:0013 1:0014 1:0015 1:0016 1:0017 1:0018 1:0019 1:0020 1:0021 1:0022 1:0023 1:0024 1:0025 1:0026 1:0027 1:0028 1:0029 1:0030 1:0031 1:0032 1:0033 1:0034 1:0035 1:0036 1:0037 1:0038 1:0039 1:0040 1:0041 1:0042 1:0085 1:0086 1:0087 1:0088 1:0089 1:0090 1:0091 1:0092 1:0093 1:0094 1:0095 1:0096 1:0097 1:0098 1:0099 1:0100 1:0101 Description AlarmMPU #1 Failed AlarmMPU #2 Failed AlarmCascade Input Failed AlarmAux Input Failed AlarmKW Input Failed AlarmSync Input Failed AlarmFirst Stage Press Input Failed AlarmRemote Speed Input Failed AlarmRemote Cascade Input Failed AlarmRemote Aux Input Failed AlarmLoadshare Input Failed AlarmActuator #1 Failed AlarmActuator #2 Failed Alarm- Start Permissive Not Met AlarmCommunication Link #1 Failed AlarmCommunication Link #2 Failed AlarmGenerator Breaker Open AlarmTurbine Trip AlarmTie Breaker Open AlarmOverspeed Alarm AlarmTie Breaker Open/No Aux AlarmGen Breaker Open/No Aux AlarmTie Breaker Open/No Casc AlarmGen Breaker Open/No Casc AlarmTie Breaker Open/No Remote AlarmGen Breaker Open/No Remote AlarmStuck in Critical Alarm Alarmspare Alarmspare Alarmspare Alarmspare Alarmspare Alarmspare Alarmspare Alarmspare Alarmspare Alarmspare OpView Alarm latch Alarm Acknowledge Alarm Exists (Common Alarm Indication) TripExternal Trip TripESD Button Remote Speed Setpt Is In Control Remote Speed Setpt Is Inhibited Spare Spare Spare Generator Breaker Closed Utility Tie Breaker Closed Synchronizing Rate Selected Synchronizing Is Enabled Sync or Load Share Is In Control Sync/Load Share Is Inhibited Spare Frequency Control Armed Frequency Control Spare Cascade Is Enabled Cascade Is Active Addr 1:0043 1:0044 1:0045 1:0046 1:0047 1:0048 1:0049 1:0050 1:0051 1:0052 1:0053 1:0054 1:0055 1:0056 1:0057 1:0058 1:0059 1:0060 1:0061 1:0062 1:0063 1:0064 1:0065 1:0066 1:0067 1:0068 1:0069 1:0070 1:0071 1:0072 1:0073 1:0074 1:0075 1:0076 1:0077 1:0078 1:0079 1:0080 1:0081 1:0082 1:0083 1:0084 1:0129 1:0130 1:0131 1:0132 1:0133 1:0134 1:0135 1:0136 1:0137 1:0138 1:0139 1:0140 1:0141 1:0142 1:0143 1:0144 1:0145
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Spare Spare Spare Spare Spare Shutdown Relay Energized Alarm Relay Energized Relay 1 Energized Relay 2 Energized Relay 3 Energized Relay 4 Energized Relay 5 Energized Relay 6 Energized ESD Contact Input Closed Reset Contact Input Closed Raise Speed Contact Input Closed Lower Speed Contact Input Closed Contact In 1 Closed Contact In 2 Closed Contact In 3 Closed Contact In 4 Closed Contact In 5 Closed Contact In 6 Closed Contact In 7 Closed Contact In 8 Closed Contact In 9 Closed Contact In 10 Closed Gen Set Configured Cascade Control Configured Remote Cascade Configured Aux Control Configured Remote Aux Configured Enables Mod1 in local Start Permissive Configured Frequency Arm/Disarm Configured Frequency Control Configured MPU 2 Configured Local/Remote Configured Local Trip Enabled Casc Tracking Configured KW Signal OK
Addr 3:0001 3:0002 3:0003 3:0004 3:0005 3:0006 3:0007 3:0008 3:0009 3:0010 3:0011 3:0012 3:0013 3:0014 3:0015 3:0016
Description Control Parameter * Speed Sensor #1 Input Speed Sensor #2 Input Actual Turbine Speed Actual Speed (%) Speed Setpoint (%) Speed Setpoint Speed Droop Setpoint Speed Droop Speed PID Output Min Governor Speed Setpoint Highest Speed Reached Idle/RatedIdle Speed Idle/RatedRated Speed Auto Seq-Low Idle Speed Setpt Auto Seq-Low Idle Delay Time
Units none rpm rpm rpm % % rpm rpm % % rpm rpm rpm rpm rpm min
Multiplier none none none none 100 100 none none 100 100 none none none none none 100
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Addr 3:0017 3:0018 3:0019 3:0020 3:0021 3:0022 3:0023 3:0024 3:0025 3:0026 3:0027 3:0028 3:0029 3:0030 3:0031 3:0032 3:0033 3:0034 3:0035 3:0036 3:0037 3:0038 3:0039 3:0040 3:0041 3:0042 3:0043 3:0044 3:0045 3:0046 3:0047 3:0048 3:0049 3:0050 3:0051 3:0052 3:0053 3:0054 3:0055 3:0056 3:0057 3:0058 3:0059 3:0060 3:0061 3:0062 3:0063 3:0064 3:0065 3:0066 3:0067 3:0068 3:0069 3:0070 3:0071 3:0072 3:0073 3:0074 3:0075 3:0076 3:0077 3:0078 3:0079 3:0080 3:0081 Description Auto Seq-Time Left At Low Idle Auto Seq-Low Idle to High Idle Rate Auto Seq-High Idle Speed Setpoint Auto Seq-High Idle Delay Time Auto Seq-Time Remaining At High Idle Auto Seq-High Idle to Rated Rate Auto SeqRated Speed Setpt Auto SeqRun Time Hours Auto SeqHours Since Alarm Cascade Setpoint (Scaled) Cascade PID Output Cascade Input (%) Cascade Setpoint (%) Cascade Scale Factor Cascade Input (Scaled) Remote Cascade Input (Scaled) Aux Setpoint (Scaled) Aux PID Output Aux Input (%) Aux Setpoint (%) Aux Scale Factor Aux Input (Scaled) Remote Aux Input (Scaled) Remote Speed Setpoint Input FSP Scale Factor FSP Input (Scaled) Loadshare Scale Factor Sync/Loadshare Input (Scaled) KW Scale Factor KW Input (Scaled) Vlv Limiter Setpt Actuator Demand Actuator 1 Demand Actuator 2 Demand Spare Spare Spare Spare Spare Spare Spare Spare Spare Modbus Entered Speed Setpoint (fdbk) Modbus Entered Cascade Setpt (fdbk) Modbus Entered Aux Setpt (fdbk) Spare Spare Spare Spare Spare Spare Spare Spare Spare Analog Input 1 Analog Input 2 Analog Input 3 Analog Input 4 Analog Input 5 Analog Input 6 Analog Output 1 Analog Output 2 Analog Output 3 Analog Output 4 Units min rpm/sec rpm min min rpm/sec rpm hrs hrs Casc units % % % none Casc units Casc units aux units % % % none aux units aux units rpm none FSP units none rpm none kW units % % % %
% % % % % % mA mA mA mA
100 100 100 100 100 100 100 100 100 100
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Description Modbus Entered Speed Setpoint Modbus Entered Casc Setpoint Modbus Entered Aux Setpoint Spare Spare Spare Spare Spare
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Analog Read addresses 3:00880093 give the configuration value of the analog inputs, one to six in order. The configuration for the analog inputs are defined in the table below.
Value 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Description Remote Speed Setpt Synchronizing Input Sync/Load Share Input KW/Unit Load Input Cascade Input Remote Cascade Setpt Auxiliary Input Remote Aux Setpt First Stage Press Input (Not Used)
Analog Read addresses 3:00940099 give the configuration value of the analog outputs, one to six in order. The configuration for the analog outputs are defined in the table below.
Value 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Description Actual Speed Speed Setpoint Remote Speed Setpt Load Share Input Sync Input KW Input Cascade Input Cascade Setpoint Rmt Cascade Setpt Auxiliary Input Auxiliary Setpoint Rmt Auxiliary Setpt Valve Limiter Setpoint Actuator Demand Readout Actuator 1 Readout Actuator 2 Readout First Stg Press Input (Not Used)
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Analog Read addresses 3:01000105 give the configuration value of the relays, one to six in order. The configuration for the relays are defined in the table below.
Value Description Relay Configured As Level Switch 0. Under speed Switch 1. Speed Level Switch 2. Speed Setpoint Level Switch 3. KW Level Switch 4. Load Share Level Switch 5. Cascade Level Switch 6. Cascade Setpoint Level Switch 7. Aux Level Switch 8. Aux Setpoint Level Switch 9. Actuator Demand Level Switch 10. Act 1 Demand Level Switch 11. Act 2 Demand Level Switch 12. Valve Limiter Level Switch 13. First Stage Pressure Level Switch Relay Configured To Indicate State 21. Shutdown Condition 22. Trip Relay (additional trip relay output) 23. Alarm Condition 24. Control Status OK 25. Overspeed Trip 26. Overspeed Test Enabled 27. Speed PID in Control 28. Remote Speed Setpt Enabled 29. Remote Speed Setpt Active 30. Underspeed Switch 31. Auto Start Sequence Halted 32. On-Line PID Dynamics Mode 33. Local Control Mode 34. Frequency Control Armed 35. Frequency Control 36. Sync Enabled 37. Sync/Load Share Active 38. Load Share Control 39. Casc Control Enabled 40. Cascade Control Active 41. Remote Casc Setpt Enabled 42. Remote Casc Setpt Active 43. Aux Control Enabled 44. Aux Control Active 45. Auxiliary PID in Control 46. Remote Aux Setpt Enabled 47. Remote Aux Setpt Active 48. Valve Limiter in Control 49. F3 Key Selected 50. F4 Key Selected 51. Modbus Command 52. (Not Used)
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Analog Read addresses 3:01060117 give the configuration value of the contact inputs, one to twelve in order. The configuration for the contact inputs are defined in the table below.
Value 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 30. 31. Description Generator Breaker Utility Tie Breaker Overspeed Test External Run Start Permissive Idle/Rated Halt/Continue Auto Start Sequence Override MPU Fault Select On-Line Dynamics Local/Remote Remote Speed Setpt Enable Sync Enable (Not Used) Freq. Control Arm/Disarm Casc Setpt Raise Casc Setpt Lower Casc Control Enable Remote Casc Setpt Enable Aux Setpt Raise Aux Setpt Lower Aux Control Enable Remote Aux Setpt Enable Valve Limiter Open Valve Limiter Close External Trip 2 External Trip 3 External Trip 4 External Trip 5 Controlled Shutdown (Manual) (Not Used)
Analog Read addresses 3:0118-0119 give the configuration value of the Aux units and the Cascade units, in order. The configuration for the units are defined in the table below.
Value 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Description psi kPa MW KW degF degC t/h k#/hr #/hr kg/cm2 bar atm (none)
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Modbus Percentage
Some of the analog read addresses have percentages sent across. The formula used in the percentage calculation is (actual/max) * 100). The percentage is multiplied by 100 before being sent across the Modbus to provide up to 2 decimal places, if desired Woodward 157
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Replacement/Exchange
Replacement/Exchange is a premium program designed for the user who is in need of immediate service. It allows you to request and receive a like-new replacement unit in minimum time (usually within 24 hours of the request), providing a suitable unit is available at the time of the request, thereby minimizing costly downtime. This is also a flat rate structured program and includes the full standard Woodward product warranty (Woodward Product and Service Warranty 5-01-1205). This option allows you to call in the event of an unexpected outage, or in advance of a scheduled outage, to request a replacement control unit. If the unit is available at the time of the call, it can usually be shipped out within 24 hours. You replace your field control unit with the like-new replacement and return the field unit to the Woodward facility as explained below (see Returning Equipment for Repair later in this chapter). Charges for the Replacement/Exchange service are based on a flat rate plus shipping expenses. You are invoiced the flat rate replacement/exchange charge plus a core charge at the time the replacement unit is shipped. If the core (field unit) is returned to Woodward within 60 days, Woodward will issue a credit for the core charge. [The core charge is the average difference between the flat rate replacement/exchange charge and the current list price of a new unit.] Return Shipment Authorization Label. To ensure prompt receipt of the core, and avoid additional charges, the package must be properly marked. A return authorization label is included with every Replacement/Exchange unit that leaves Woodward. The core should be repackaged and the return authorization label affixed to the outside of the package. Without the authorization label, receipt of the returned core could be delayed and cause additional charges to be applied.
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CAUTION
To prevent damage to electronic components caused by improper handling, read and observe the precautions in Woodward manual 82715, Guide for Handling and Protection of Electronic Controls, Printed Circuit Boards, and Modules.
Packing a Control
Use the following materials when returning a complete control: protective caps on any connectors; antistatic protective bags on all electronic modules; packing materials that will not damage the surface of the unit; at least 100 mm (4 inches) of tightly packed, industry-approved packing material; a packing carton with double walls; a strong tape around the outside of the carton for increased strength.
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NOTE
We highly recommend that you make arrangement in advance for return shipments. Contact a Woodward customer service representative at 1 (800) 523-2831 in North America or +1 (970) 482-5811 for instructions and for a Return Authorization Number.
Replacement Parts
When ordering replacement parts for controls, include the following information: the part number(s) (XXXX-XXXX) that is on the enclosure nameplate; the unit serial number, which is also on the nameplate.
You can also contact the Woodward Customer Service Department or consult our worldwide directory on Woodwards website (www.woodward.com) for the name of your nearest Woodward distributor or service facility.
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Engineering Services
Woodward Industrial Controls Engineering Services offers the following aftersales support for Woodward products. For these services, you can contact us by telephone, by email, or through the Woodward website. Technical Support Product Training Field Service
Contact information: Telephone+1 (970) 482-5811 Toll-free Phone (in North America)1 (800) 523-2831 Emailicinfo@woodward.com Websitewww.woodward.com Technical Support is available through our many worldwide locations or our authorized distributors, depending upon the product. This service can assist you with technical questions or problem solving during normal business hours. Emergency assistance is also available during non-business hours by phoning our toll-free number and stating the urgency of your problem. For technical support, please contact us via telephone, email us, or use our website and reference Customer Services and then Technical Support. Product Training is available at many of our worldwide locations (standard classes). We also offer customized classes, which can be tailored to your needs and can be held at one of our locations or at your site. This training, conducted by experienced personnel, will assure that you will be able to maintain system reliability and availability. For information concerning training, please contact us via telephone, email us, or use our website and reference Customer Services and then Product Training. Field Service engineering on-site support is available, depending on the product and location, from one of our many worldwide locations or from one of our authorized distributors. The field engineers are experienced both on Woodward products as well as on much of the non-Woodward equipment with which our products interface. For field service engineering assistance, please contact us via telephone, email us, or use our website and reference Customer Services and then Technical Support.
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Technical Assistance
If you need to telephone for technical assistance, you will need to provide the following information. Please write it down here before phoning:
General
Your Name Site Location Phone Number Fax Number
Control/Governor Information
Please list all Woodward governors, actuators, and electronic controls in your system:
Woodward Part Number and Revision Letter Control Description or Governor Type Serial Number Woodward Part Number and Revision Letter Control Description or Governor Type Serial Number Woodward Part Number and Revision Letter Control Description or Governor Type Serial Number
If you have an electronic or programmable control, please have the adjustment setting positions or the menu settings written down and with you at the time of the call.
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Date ___________
SPEED SETPOINT VALUES Overspeed Test Lmt (rpm) Overspeed Trip (rpm) Max Governor Speed (rpm) Min Governor Speed (rpm) Setpt Slow Rate(rpm/sec) Use Remote Speed Setpt ? Rmt Spd Setpt Max Rate Use Critical Speeds? Critical Speed Rate Critical Speed 1 Max Critical Speed 1 Min Use Critical Band 2 ? Critical Speed 2 Max Critical Speed 2 Min
rpm rpm rpm rpm rpm/sec YES ____NO _____ rpm/sec YES _____ NO _____ rpm/sec rpm rpm YES _____NO _____ rpm rpm
OPERATING PARAMETERS Generator Application? YES _____NO _____ Use Gen Brkr Open Trip ? YES _____NO _____ Use Tie Brkr Open Trip ? YES _____NO _____ Use KW Droop? YES _____NO _____ KW Max Load __________KW Droop (%) % Rated Spd Setpt rpm Use Freq Arm/Disarm ? YES _____ NO _____ Use Local/Remote YES _____ NO _____ DRIVER CONFIGURATION Act #1 is 420 mA? Invert Driver Outputs ? Use Act 1 Flt Shutdown Act #1 Dither Use Actuator #2? Act #2 is 420 mA? Act #2 Offset (%) Use Act 2 Flt Shutdown Act #2 Dither (%) Use Act #2 as Readout? Act #2 Readout is: Readout 4 mA Value Readout 20 mA Value
YES _____NO _____ YES _____NO _____ YES _____NO _____ % YES _____NO _____ YES _____NO _____ % YES _____NO _____ % YES _____NO _____ % Units Units
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ANALOG INPUTS Analog Input # 1 Function Input 1 4 mA Value Input 1 20 mA Value Analog Input # 2 Function Input 2 4 mA Value Input 2 20 mA Value Analog Input # 3 Function Input 3 4 mA Value Input 3 20 mA Value Analog Input # 4 Function Input 4 4 mA Value Input 4 20 mA Value Analog Input # 5 Function Input 5 4 mA Value Input 5 20 mA Value Analog Input # 6 Function Input 6 4 mA Value Input 6 20 mA Value CONTACT INPUTS Contact Input 1 Function Contact Input 2 Function Contact Input 3 Function Contact Input 4 Function Contact Input 5 Function Contact Input 6 Function Contact Input 7 Function Contact Input 8 Function Contact Input 9 Function Contact Input 10 Fctn Contact Input 11 Fctn Contact Input 12 Fctn FUNCTION KEYS F3 Key Performs Blink when not Active? F4 Key Performs Blink when not Active? AUXILIARY CONTROL Use Auxiliary Control ? Lost Aux Input Shutdown? Use KW Input ? Invert Aux ? Min Aux Setpt Max Aux Setpt Aux Setpt Rate units/sec Use Aux Enable? Setpt Initial Value Aux Droop Aux PID Prop Gain Aux PID Integral Gain Aux Derivative Ratio Tiebrkr Open Aux Disable Genbrkr Open Aux Disable Use Remote Aux Setting Remote Aux Max Rate Aux Units of Measure
Units Units Units Units Units Units Units Units Units Units Units Units
YES _____NO _____ YES _____NO _____ Units Units Units/sec YES _____NO _____ Units rpm rpm rpm/Sec % % rps % YES _____NO _____ Units/sec
Units Units Units Units Units Units Units Units Units Units Units Units
YES _____ NO _____ YES_ ____ NO _____ YES _____ NO _____ YES _____ NO _____ Units Units Units/sec YES _____ NO _____ Units % % rps % YES ____NO _____ YES ____NO _____ YES _____ NO ____ Units/sec
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YES ____NO _____ YES ____NO _____ Units Units YES _____NO _____ YES ____NO _____ Units Units YES _____NO _____ YES ____NO _____ Units Units YES _____NO _____ YES ____NO _____ Units Units YES _____NO _____ YES ____NO _____ Units Units YES _____NO _____ YES ____NO______ Units Units
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We appreciate your comments about the content of our publications. Send comments to: icinfo@woodward.com Please include the manual number from the front cover of this publication.
PO Box 1519, Fort Collins CO 80522-1519, USA 1000 East Drake Road, Fort Collins CO 80525, USA Phone +1 (970) 482-5811 Fax +1 (970) 498-3058
Email and Websitewww.woodward.com Woodward has company-owned plants, subsidiaries, and branches, as well as authorized distributors and other authorized service and sales facilities throughout the world. Complete address / phone / fax / email information for all locations is available on our website.
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